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.
TATA DRG. NO.
REV. NO.
TATA CONSULTING ENGINEERS LIMITED

CONSULTANT
MUMBAI
TECHNOLOGY
PARTNER
INDIAN PARTNE LARSEN & TOUBRO LIMITED

R
PROJECT G1680 – TATA STEEL Ltd. – Jamshedpur - India – CDQ COP #10/#11
TITLE CDQ10 / CDQ11 COMMISSIONING MANUAL
PWIT NUMBER 1680 50 K JM 001 REV. 1
PERUGI AFI AEO

PREPARED BY CHECKED BY APPROVED BY
20/09/2016 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
LARSEN & TOUBRO LIMITED

1680 50 K JM 001 Page: 2
4
3
2
1 Final Revision 28/08/2016 PERUGI AFI AEO
0 First Issue 20/09/2016 PERUGI AFI AEO
RE PREPARE APPROVE APPROVED
DESCRIPTION DATE CHECKED
V. D D BY OWNER

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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 Basic safety instruction ....................................................................................... 6
1.2 Commissioning Plan ............................................................................................ 6
1.3 Preparation of Commissioning – General Instructions ...................................... 9
1.4 Preparation of Commissioning – Cleaning, Flushing and Drying.................... 10
1.5 Preparation of Commissioning – Leakage / Pressure test ............................... 11
1.6 Preparation of Commissioning – Functional tests ........................................... 11
1.7 Preparation of Commissioning – Inertization ................................................... 13
1.8 Preparation of Commissioning – Try-out drains .............................................. 13
2. BASIC SAFETY INSTRUCTION ............................................................... 14
2.1 Type of users...................................................................................................... 14
2.2 Intended use ....................................................................................................... 14
2.3 Safety notes and symbols ................................................................................. 15
2.4 General safety remarks ...................................................................................... 15
2.5 Symbols and warning signs used in the manual .............................................. 17
2.6 Type of symbols and warning signs used in the Plant..................................... 19
2.7 Residual risks and prevention/protection measures ........................................ 23
2.8 Safety Data Sheets ............................................................................................. 33
2.9 Applicable standards ......................................................................................... 33
2.10 Plant owner duties and obligations................................................................... 34
2.11 Operators duties and obligations ...................................................................... 37
3. SINGLE TEST COMMISSIONING PROCEDURE .................................... 38
3.1 Sub Supplier manuals and instruction for Commissioning ............................. 38
3.2 Single Test Trial For Area 01 – ECR .................................................................. 44
3.3 Single Test Trial For Area 02 – BAR .................................................................. 50
3.4 Single Test Trial For Area 03 – RACK ............................................................... 53
3.5 Single Test Trial For Area 04 – Hot Coke transportation (from COB) .............. 56
3.6 Single Test Trial For Area 05 - Hot coke charging system ............................... 59
3.7 Single Test Trial For Area 06 – CDQ CHAMBER ............................................... 62
3.8 Single Test Trial For Area 07 – Cooled coke Discharging system................. 66
3.9 Single Test Trial For Area 08 – Primary Gas Catcher (PDC Area) .................... 71
3.10 Single Test Trial For Area 09 – Boiler Circuit (Boiler Area) .............................. 73
3.11 Single Test Trial For Area 10 – Cooling Gas Circuit ......................................... 76
3.12 Single Test Trial For Area 11 – Coke Breeze Circuit Area ................................ 79
3.13 Single Test Trial For Area 12 – Environmental dedusting (DE Area) & DE Coke
dust Circuit (DE Dust Area) .............................................................................. 81
3.14 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 Summary of test to be executed on Fluid and Process lines ........................... 85
4.2 CDQ Gas Circuit Leakage test Procedure ......................................................... 86
4.3 Air dilution Line Leakage test Procedure.......................................................... 87
4.4 Utilities Lines Flushing and pressure test Procedures .................................... 90
4.5 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 CDQ Integrated COLD Test ................................................................................ 93
6.2 Boiler Integrated test ......................................................................................... 97
7. HEATING UP AND RAMP UP TO OPERATION .................................... 100
7.1 Heating Up Preconditions ................................................................................ 100
7.2 Heating up curve .............................................................................................. 101

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7.3 Hot Air Drying ................................................................................................... 104

7.4 COG HEATING UP ............................................................................................ 107
7.5 ALKALI BOILING PROCEDURE ....................................................................... 110
7.6 Cooling down of System.................................................................................. 110
7.7 Drying and Hot coke heating ........................................................................... 110
7.8 Stabilization of operation and preparation to Performance ........................... 111
8. 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.

1680 50 K JM 001 Page: 21
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
Unstable explosives
Explosives, divisions 1.1, 1.2, 1.3, 1.4
Exploding bomb
Self-reactive substances and mixtures, types A, B
Organic peroxides, types A, B
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
Flame
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
Oxidizing gases, category 1

Flame over circle Oxidizing liquids, categories 1, 2, 3
Oxidizing solids, categories 1, 2, 3
Compressed gases
Liquefied gases
Gas cylinder
Refrigerated liquefied gases
Dissolved gases
Corrosion Corrosive to metals, category 1
Explosives, divisions 1.5, 1.6

Flammable gases, category 2
no pictogram required no pictogram required
Self-reactive substances and mixtures, type G
Organic peroxides, type G

1680 50 K JM 001 Page: 22
HEALTH HAZARDS
Acute toxicity (oral, dermal, inhalation), categories 1, 2,

Skull and crossbones
3
Acute toxicity (oral, dermal, inhalation),category 4

Skin irritation, categories 2, 3
Eye irritation, category 2A
Skin sensitization, category 1
Specific target organ toxicity following single exposure,
category 3
Respiratory tract irritation
Exclamation mark
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

Corrosion
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 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

no pictogram required no pictogram required Eye irritation, category 2B
Reproductive toxicity – effects on or via lactation

1680 50 K JM 001 Page: 23
ENVIRONMENTAL HAZARDS
Acute hazards to the aquatic environment, category 1

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

2, 3
no pictogram required no pictogram required
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

1680 50 K JM 001 Page: 24
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 STEP 2b STEP 2c STEP 3
Injury (I) Frequency (F) Avoidance (A) Probability (P)
Severity of possible injury Frequency / duration of Possibility of avoiding or Probability of harm occurence
exposure to the hazard limiting the harm P0 P1 P2 P3
A1 R1 R1 R2 R3
I1 NA
A2 R1 R2 R3 R4
A1 R3 R3 R4 R5
F1
A2 R3 R4 R5 R6
I2
A1 R4 R5 R6 R7
F2
A2 R4 R6 R7 R8
A1 R5 R7 R8 R9
F1
A2 R5 R8 R9 R10
I3
A1 R6 R9 R10 R11
F2
A2 R6 R10 R11 R12
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.

1680 50 K JM 001 Page: 25
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

1680 50 K JM 001 Page: 26
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

1680 50 K 02 003/004
A4.3 52/53 Heat Recovery Steam Generator (Boiler Shell)
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

1680 50 K 02 003/004
A8 80 Nitrogen Network
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

O15044-0F2-M-B-0159-001/0
A20 54 CDQ Dedusting Line
02
1680 53 G 02 001/011
Heat Recovery Steam Generator 1680 53 G 02 002/012
A21 53
(BOILER PROPER) 1680 53 G 02 003/013
1680 53 G 02 004/014
A100 Walkways
A200 Support structures

1680 50 K JM 001 Page: 27
Mechanical Hazards
Risk Residual risk Area Mitigations measures Signs
Elements with shar In protective/insulation All Use safety gloves (E

p edges: e.g. struct materials N381) and safety sho Protective
ures, sheet edge of es (S3 EN ISO 2034 gloves
5)
protection/insulation against cutting
materials
Safety
shoes
Warning:
Sharp
Element
Work near accessib During work near acc It is forbidden to rem
le moving parts essible moving eleme ove the protections.
(Impact, Entanglem nts No
ent, Shearing) Annual check of the reaching in
All, efficiency of the
in prese protection.
Work on moving During work on movi nce of Cut and clamp energy Disconnect
elements without ng elements mobile e
before
power outage lements sources before workin carrying ou
(Impact, Entanglem g t
ent, Shearing) or remove protection. maintenanc
e or repair
Fall of not fixed or In case of incorrect ALL Periodic inspections:
unsafe structures maintenance Annual control of: bo
(Crushing) lt
tightening, welded join
t, corrosion
Every 5 years: check
for cracks and distort
ions in beams and ca
twalks
Fall of material due In case of incorrectm A100 Respect the capacity
aterial movements limits of structures
No heavy
to deposit of unstab
loads
le material or overl
oad
Fall of person from In case of failure to f A100 It is forbidden to rem
ollow the indications ove the protections
high levels (gravity) and lack of shields Warning
Annual check of the drop (fall)
shields against fall do
wn
Release of In case of incorrect A4, A8, Block the vents in
pressurized fluids maintenance A10, A1 case of work near
(being run over, 6, A17, them
being thrown, A21 Warning
impact due Every 5 years check pressurized
to ruptures) the piping and cylinder
vessel conservation
(VT, PT, UT)

1680 50 K JM 001 Page: 28
Follow the
specifications of
component manuals
about control, use
and maintenance
Electrical Hazards
Direct/indirect conta In case of incorrect All Cut and clamp energy Disconnect
ct with live compon maintenance sources before worki mains plu
ents (electrocution) ng g from
Warning: electricity electrical
outlet
Warning el
ectricity
Overload/short circui In case of incorrect All Follow the specificatio

ts components (bur maintenance ns of electrical compo
n, fire/explosion) nents manuals about
control, use and main
tenance
Thermal Hazards
Direct contact with In case of accidental Use the safety gloves

not insulated piping contacts Do not
and vessel with T (EN 702) against burn touch
>40°C (burns) s
Warning
hot surface
Investment by relea In case of incorrect Block the vents in the

se of hot fluids (bur maintenance
ns) case of work near the
m.
All
Annual monitoring su
General
rface temperature of t
warning
he pipe (with thermal
sign
imaging camera to hi
Danger of
ghlight anomalies)
burns
Every 5 years check t
and/or
he piping and vessel
scalds
conservation (VT, PT,
UT).
Follow the specificatio
ns of component man
uals about control, us
e and maintenance

1680 50 K JM 001 Page: 29
Flammable fluid los In case of incorrect A4 Block the vents in the

s, with ignition sour maintenance A13 case of work near th
ce (Fire/Explosion) em. No open
flame
Annual monitoring
surface temperature o
f
the pipe (with thermal Warning
imaging camera to flammable
highlight anomalies) material
Every 5 years check
the piping and vesse
l conservation (VT, P
T, UT), Warning
Follow the specificatio explosive
ns of component man material
uals about control, us
e and maintenance
Noise
Exposure to Close to high noise All The level of emitted n

continuous noises levels zone 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.
Exposure to sudden Close to high noise All Hearing protection SN
R 34 dB (EN 352)
noises from leakage levels zone Wear ear
of fluid under protections
pressure (flanges,
valves, hoses)

1680 50 K JM 001 Page: 30
Materials/Substances
Release of toxic flui Close to the relea A2 Use personal Wear

ds (poisoning toxic) se zone A4 multifunctional detector respiratory
A8 s
A13 (CO, H2S, etc) protection
A21
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 Warning
Every 5 years check toxic
material
the piping and vessel
conservation
(VT, PT, UT)
In case of emergency,
before to access to pl
ant check the wind so
cks
for direction of wind
Use showers and
eyewash systems
Flammable fluid loss In case of incorre A4 Block the vents in the
, with ignition sourc ct maintenance A13 case of work near th No open
e em. flame
(Fire/Explosion)
Every 5 years check
the piping and vessel Warning
conservation (VT, PT, flammable
UT). material
Follow the specificatio
ns of component man
uals about control, us Warning
e and maintenance explosive
material
Internal In case of incorre A4 Remember to inertize

flammable/explosive ct inertization of pi A13 the piping before put i
atmosphere ping/vessel contain n services
after maintenance ing
flammable/oxidizing
fluids

1680 50 K JM 001 Page: 31
Release of Close to the relea All inertize Every 5 years check

asphyxiating gas se zone or into th d pipes / the piping and vessel
e inertized piping/v shells conservation (VT, PT, General
essel UT). warning
Follow the specificatio "Danger of
ns of component man suffocatin
uals about control, us g due to
e and maintenance escape of
Before to access the i inert gas"
nerted pipes, relief of
the O2 concentration.
Release of cancerou Close to the relea A4 Necessary Health prot
s gas se zone A13 ocols (periodic checks)
as indicated by
national laws.
Respect the indication
Wear
s
respiratory
reported in safety data
protection
sheets of cancerous
substances
PPE: Full face

respiratory protections

1680 50 K JM 001 Page: 32
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
In the following, other PPE are indicated for t

Protective clothing 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.

1680 50 K JM 001 Page: 33
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.

1680 50 K JM 001 Page: 34
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.

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.

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 self-
protection.
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).

1680 50 K JM 001 Page: 37
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.

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.

1680 50 K JM 001 Page: 39
3.1.1 Sub Supplier Manuals and Instruction for Commissioning for Mechanical Items
VENDOR
AREA Detail Description DOCUMENT ID
NAME
CDQ - MECHANICAL ITEMS
02 ITEMS FOR BAR

168053GM3001/101
BFW Pumps THERMAX
168053GM2001/101
Pumps: 10.5.1.8
WILO MATHER &
Booster Pump 10.5.1.8.1
PLATT
WILO MATHER &
Deaerator Feed Pump 10.5.1.8.2
PLATT
WILO MATHER &
Deaerator Circulation Pump 10.5.1.8.3
PLATT
WILO MATHER &
Industrial Water Pump 10.5.1.8.4
PLATT
Crane VVFF Panels / PLC DHHI 168080EM1150/250
168080IM2104/204
CDQ PLC PW-Infinity 168080IM2102/202
168080IM2101/201
04 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
05 ITEMS FOR COKE CHARGING
Automatic Positioning System (APS) DHHI L&T - 10.1.3

168051FEM312
Crane DHHI
168051FEM315
Charging System IHI-PW 168051KM1002
06 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
10.5.4.2
ber bypass

1680 50 K JM 001 Page: 40
VENDOR
AREA Detail Description DOCUMENT ID
NAME
ITEMS FOR COKE DISCHARGING DEVICE

07
FOR COOLED COKE
Vibrating feeder 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 L&T - 10.1.5.1.1

JOYA
Pulley and Deflector Rollers ENGINEERING L&T - 10.1.5.1.2
INDUSTRIES
JOYA
Idlers ENGINEERING L&T - 10.1.5.1.3
INDUSTRIES
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

1680 50 K JM 001 Page: 41
AREA Detail Description VENDOR DOCUMENT ID

NAME
08 ITEMS FOR PRIMARY DUST CATCHER

Primary dust catcher 10.3.2.1
Steam Bleeding Device 10.3.4.4
09 ITEMS FOR BOILER AREA
HRSG BOILER PROPER THERMAX 168053GM2001/101
168053GM3001/101
HRSG BOILER AUXILIARIES THERMAX 168053GM2001/101
168053GM3001/101
SUB-ECONOMIZER THERMAX 168053GM2001/101
168053GM3001/101
Boiler Instruments L&T L&T - 10.5.21
10 ITEMS FOR GAS CIRCULATION SYSTEM
Gas circulation blower L&T - 10.3.1

Gas circulation blower L&T - 10.3.1.1
Motor for gas circulation blower L&T - 10.3.1.2
Emergency Flaring system L&T - 10.3.3
High & Low Temperature Expansion Joints L&T - 10.5.12
11 Coke breeze discharge equipment for primary dust ca L&T - 10.3.4
tcher & Secondary Dust Catcher
Coke Breeze Bunker L&T - 10.3.4.1

Rotary Seal Valve / Rotary Airlock Valve L&T - 10.3.4.2
Manual Slide Gate L&T - 10.3.4.3
Chain Conveyor L&T - 10.3.4.6
Bucket conveyor L&T - 10.3.4.7
Coke dust hopper L&T - 10.3.4.9
Telescopic chute L&T - 10.3.4.10
Pug-mill L&T - 10.3.4.11
12 ITEMS FOR DUST EXTRACTION SYSTEM 10.4
Bag filter proper L&T - 10.4.1
Bag filter proper with spark arrestor L&T - 10.4.1.1
Manual Slide Gate L&T - 10.4.1.2
Rotary Airlock Valve L&T - 10.4.1.3
Chain conveyor L&T - 10.4.1.4
Bucket conveyor L&T - 10.4.1.5
Dust Storage Silo L&T - 10.4.1.6
Pug-mill L&T - 10.4.1.7
Plant Dedusting Fans L&T - 10.4.1.8
Chute L&T - 10.4.1.9

1680 50 K JM 001 Page: 42
AREA Detail Description VENDOR DOCUMENT ID

NAME
13 OTHERS 10.5
Hanger for main steam piping L&T - 10.5.1.1
Electrical Hoists L&T - 10.5.1.2
Jib crane L&T - 10.5.1.9
Manual Hoists L&T - 10.5.1.3
Fire Hydrant Valves, Fire Hose and Hose Box L&T - 10.5.1.4
Chemical (Acid) Dosing System L&T - 10.5.1.6
Insulation L&T - 10.5.1.7
Pipe & Fittings L&T - 10.5.3
Valves L&T - 10.5.4
Manual Valves L&T - 10.5.4.1
Boiler related Valves L&T - 10.5.4.3
Fabrication Items for CDQ 10 Equipment L&T - 10.5.5
DM storage Tank L&T - 10.5.11
Expansion Joints for Dedusting / Expansion Joints f L&T - 10.5.13
or pumps
Dampers L&T - 10.5.14
Submersible sump pump L&T - 10.5.20
Elevator THYSSEN L&T - 10.2.2.5
KRUPP
Instrumentation TDS Various I01 –I23
LT Motors Catalogue L&T – E.07

1680 50 K JM 001 Page: 43
3.1.2 Sub Supplier manuals and instruction for Commissioning for

Electrical/instrumentation Items
Document Commissioning
Detail Description VENDOR
N° 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
01
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 Pressure gauge Forbes marshall
I.2 Pressure transmitter Yokogawa
I.3 Pressure switch Baumer
I.4 Orifice plate M/S GIC
I.5 Magnetic flow meter Yokogawa
I.6 Temperature Transmitter Yokogawa
I.7 Level switch FELLOW KOGYO
I.8 Radar type level transmitter E&H
I.9 Thermocouple Tempsen
I.10 Differential pressure type Flow transmitter Yokogawa
I.11 RTD Tempsen
I.12 Differential pressure Transmitter M/s yokogawa
I.13 Opacity Meter Chemtrol
I.14 Vibration monitoring System Scheink
I.15 Instrument cable M/S Udey pyro
I.16 CCTV M/S Wizertech
Control valves Fouress India, EME
I.17
RSON
I.18 Pyrometer M/S ICS
I.19 Oxygen Analyser M/S Yokogawa
I.20 UPS Hirel
I.21 Waste Gas Analyser M/S ABB
I.22 FO cable Lapp
I.23 DP Level Switch M/S Yokogawa

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.

1680 50 K JM 001 Page: 45
3.2.3 Commissioning Procedure
Please refer to following tables for single test info for any equipment.
REFERENCE MANU
EQUIPMENT ACTIVITIES
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
See Manual (L&T ref
Interconnection with upstream equipment erence number E.1
6.6kV Switchboard and E.2) for Test ex
Erection completion test
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)
REFERENCE MANU
AL
0. Technical Data
6.6/0.433 kV 2500 kVA

6.6kV power at feeder available
Star Point grounding
instrument-equipment/control panel wiring co
mpleted See Manual (L&T ref
6.6/0.433kV power Erection completion (outgoing cable disconne erence number E.3)
transformer cted) for Test execution a
Erection completion test nd Test acceptance
protocols
Tests
Assembly check
Operation test (tap-changer maneuvers, etc.)
Functional test (instruments signal, equipmen
t signal etc.)

1680 50 K JM 001 Page: 46
REFERENCE MANU
AL
Technical Data
6.6kV 1355kW VFD

6.6kV power at feeder available
110VAC control power supply available
Interconnection with upstream equipment
See Manual (L&T ref
erence number E.10)
6.6kV VFD for Test execution
Tests and Test acceptance
protocols
t signal etc.)
SAT 6.6kV motor
Direction of rotation check
Operation test (Start&stop, etc.)
REFERENCE MANU
AL
Technical Data
690V 360kW VFD

690V power (from Converter Transformer) at
feeder available
110VAC control power supply available
Interconnection with upstream equipment See Manual (L&T ref
erence number E.4)
690V VFD for Test execution a
nd Test acceptance
Tests protocols
t signal etc.)
SAT 690V motor

1680 50 K JM 001 Page: 47
REFERENCE MANU
AL
Technical Data
415V 500kVA

0.415kV at feeder
See Manual (L&T ref
415V Diesel Gener erence number E.5)
ator with AMF pan Erection completion test for Test execution a
el nd Test acceptance
protocols
Tests
Operation test (Start&stop sequence, etc.)
t signal etc.)
REFERENCE MANU
AL
Technical Data
415V 4000A

0.415 kV at feeders available
Interconnection with downstream equipment
Instrument-equipment/control panel wiring co
mpleted See Manual (L&T ref
erence number E.6)
PCC, MCC, PDB for Test execution a
nd Test acceptance
Tests protocols
Operation test (opening CB, closing CB, DS
maneuvers, etc.)
Functional test (interlocking, field signal, etc.)
SAT motor

1680 50 K JM 001 Page: 48
REFERENCE MANU
AL
Technical Data
415V 150Ah

Batteries ready See Manual (L&T ref
erence number E.8)
Battery Charger for Test execution a
Internal wiring completed
nd Test acceptance
Erection completion test protocols
Tests
Operation test
Functional test
REFERENCE MANU
AL
Technical Data
415V 2x40kVA

Batteries ready See Manual (L&T ref
erence number E.9)
UPS for Test execution a
Internal wiring completed
nd Test acceptance
Erection completion test protocols
Tests
Operation test
Functional test

1680 50 K JM 001 Page: 49
REFERENCE MANU
AL
Technical Data
Capacity:
Power:
PLC and RIO panels positioned with power
supply and I/O wired with cold test
Control room with server, HMI station, printer
s, networks panels positioned and with powe See Sub Vendor Ma
r supply nual for single test e
All network and field bus related to Automati xecution and Single
on System wired test acceptance prot
PLC and RIO
ocols
Tests
Final test acceptance
PLC/RIO communication protocol and compl
PLC CPU & Server redundancy etion by L&T
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

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

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)
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
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.

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
Building Erection completion
Fresh Water Booster Pumps
□ Power □ Mechanical □ Oil □ Grease
Demi Water Pumps □ Instruments □ Interlock □ Limit switch
□ Electric motor
Cooling Water Booster Pum
ps Check list
□ Check power supply system
Chemical Injection skid □ Check the mechanical rigging
SWAS □ 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 □ drinking water
□ alarm system □ Control system
Check list

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

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
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

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.
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 □Interlock
Waste water network, including draina
ges Check list
Instrument air line □ Valve installation

Compressed air line □ Instrumentation installation
Nitrogen Line
□ Piping class compliance
□ P&ID compliance
COG Line
□ Insulation where foreseen
LP Steam Line
□ Cable Feeder connection
HP steam line
□ Signal connection
Tests
□ Flushing
□ Pressure Test / Hydrotest
□ Inertization (for COG)
□ Acceptance test
□ IBR test where required

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

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

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.

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
According the method desc
□ Check power supply system ribed in "Operation manual
□ Check control power system for locomotive car" №A32
□ Check the mechanical rigging 1000119DMS by DHHI Ltd
□ Check limit switch and instrumen
tation
Tests
□ Test run
□ Cold Test
Acceptance procedure by L
□ Acceptance test &T/TSL
Coke bucket car Precondition
□Power □Mechanical
Check list According the method desc
ribed in "Operation manual
□ Check power supply system for bucket car" №A32040
□ Check the mechanical rigging 0138MS by DHHI Ltd
Tests
□ Cold Test □ Bucket rotation
Acceptance procedure by
□ Acceptance test DHHI
Bucket Precondition
□Mechanical According the method desc
Check list ribed in "Operation manual
□ Check the mechanical rigging for bucket car" №A32040
0138MS by DHHI Ltd
Tests
□ Cold Test
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.

1680 50 K JM 001 Page: 59
3.6 Single Test Trial For Area 05 - Hot coke charging system
Hot coke charging system deals of following equipment:

§ APS (automatic positioning system)
§ Automatic Charging crane
§ Charging system
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

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.
APS Precondition
□ Power □ Mechanical □ Compresso
r air
□ Oil □ Instruments □Interlock
□Limit switch □ Electric motor □Pump
Check list
□ Check power supply system According the method describe
□ Check control power system d in "Operation Manual" Produc
□ Check travel system t Code:A32990004DMS (Part
7 Electrical Manual) page 23 -
□ Check mechanical and hydraulic system 28; paragraph 3.3. - 3.5. and
□ Check air compressor system "Operation Manual" Product Co
□ Check oil system de: A329900004; page 22 - 23
; paragraf 3.5. - 3.7. by DHHI
□ Check instrumentetion and limit switch
□ 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 Acceptance procedure by DHHI
Charging Crane Precondition
□ Power □ Mechanical □ Oil
□ Grease
□ Instruments □ Interlock □ Limit switch
□Electric motor
Check list
□ Check power supply system For Crane See DHHI crane Ac
ceptance protocol for commissi
□ Check control power system oning.
□ Check driving system and brakes See Attached Detailed Crane c
□ Check lifting system and brakes ommissioning Procedure for co
mmissioning sequence informati
□ Check greasing on and duration.
□ Check instrumentation and limit switch
□ Check interlock
□ Check electric motors
Tests
□ Cold Test
□ Static Test □ Dynamic Test
□ Acceptance test Acceptance module By DHHI

1680 50 K JM 001 Page: 61
Charging Precondition
system
□Power □Mechanical □Compres
sor air
□N2 □Instrument air □Instr
uments
□Limit switch □Electric cylinder □Gr
ease
Check list According the method describe
d in "Commissioning manual fo
□ Check power supply system r charging devise" №V007T787
□ Check control power system page 3 - 7; paragraf 3.3. - 4.
□ Check driving system 1. by IHI Paul Wurth Co. LTD
□ Check greasing system and greasing b
earings
□ Check instrumentetion and limit switch
□ Check electric cylinder
Tests
□ Cold Test
□ Acceptance test Acceptance procedure by PW
Water seal unit Precondition
□Industrial water □Compressed air
□Mechanical
According the method describe
Check list d in "Commissioning manual fo
□ Check industrial water system r charging devise" №V007T787
□ Check drain water system page 3 - 7; paragraph 3.3. -
4.1. by IHI Paul Wurth Co. LT
□ Check operation of the pneumatic valve D
□ Check water level adjustment in water
seal trough
Tests
□ Cold Test
□ Acceptance test Acceptance procedure by PW

1680 50 K JM 001 Page: 62
3.7 Single Test Trial For Area 06 – CDQ CHAMBER
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
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

1680 50 K JM 001 Page: 63
3.7.5 Dilution Air Blower with motor

1680 50 K JM 001 Page: 64
Upper bleeder valv Precondition

e
□Power □Mechanical □Cooling water □Inst
rumentation
Check list
PAT standard for valve
□ Check the mechanical rigging
□ Check instrumentation
□ Check the cooling water line
Tests
□ Cold Test
By - pass valve Precondition
□Power □Mechanical □ Instrument
□Cooling water
Check list
PAT standard for valve
□ Check the cooling water line
Tests
□ Cold Test
Quenching chamber Precondition
□ Power □ Instrumentation
□ Mechanical □ N2
Check list
According to the method de
□ Check power supply system scribed in "Commissioning
□ Check instrumentation manual" №V005T195 by IHI
Paul Wurth Co, LTD
□ Check the N2 line
Tests
□ Cold Test
Acceptance procedure by P
□ Acceptance test W

1680 50 K JM 001 Page: 65
Dilution Air Fan an Precondition

d air line
□ Power □ Mechanical □ Instruments
□ N2 □ Electrical motor
Check list
□ Check control power system See Vendor Manual
Tests
□ Cold Test
Blowing device an Precondition
d gas manifold
□ Mechanical □ Instruments
□ N2
Check list According the method descr
ibed in "Commissioning ma
□ Check the mechanical rigging nual" №V005T195 by IHI P
□ Check instrumentation aul Wurth Co, LTD
Tests
□ Pre Test (manual valve position)
Acceptance procedure by P
□ Acceptance test W

1680 50 K JM 001 Page: 66
3.8 Single Test Trial For Area 07 – Cooled coke Discharging

system
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)
Discharge system capacity: 100 tph

3.8.3 Motorized gate valve

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:

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:

1680 50 K JM 001 Page: 69
For Commissioning protocols, see dedicated manual of Slide gate, vibrating feeder, Rotary seal
valve.
Rod Gate / sli Precondition

de gate valve
□ Limit switch □ Electric motor □ N2
Check list
□ Check power supply system See Vendor Manual for mec
□ Check adjustment of the limit switches hanical test
□ Check N2 line
Tests
□ Cold Test
□ Acceptance test Accept. procedure by L&T
Vibrating syste Precondition
m
□Power □Mechanical □Electrical According the method descri
magnet vibrator bed in "Installation instructio
Check list ns Opereting instructions Ma
gnet vibrator Type TS №S4
□ Check power supply system 10041R02" page 16 - 23; p
□ Check the mechanical rigging aragraf 7 - 8.1.2. and "Servi
ce handbook Vibrating feede
Tests r" №VFE-C125/240TA
□ Cold Test
□ Acceptance test Accept. procedure by L&T

1680 50 K JM 001 Page: 70
RSV Precondition
□ Power □ Mechanical □ Instrumentation
□ Grease □ Electrical motor □ N2
Check list
□ Check control power system See Vendor catalogues for I
□ Check the mechanical rigging nstallation and check
□ Check instrumentation and interlock sys
tem
□ Check the greasing of bearings
Tests
□ Cold Test
Acceptance procedure by cu
□ Acceptance test stomer
EJ and connec Precondition
tion chute
Check list
□ Visual inspection see BE and DE drawings a
□ EJ proper installation nd EJ manuals
□ Connection chute liners position
□ Passage section of coke as per
PW-Steel Plantech drawings
Tests Acceptance procedure by L

&T
Conveyor belts Precondition
□ Industrial water □ Alarm system
□ Instrument air
Check list
see vendors manual for BC
□ Check the mechanical rigging parts test
□ Check instrumentation & alarm system
□ Check the industrial water system (For
emergency spraying)
Tests
□ Cold Test
- Interlock test for emergency stops
Acceptance procedure by L
□ Acceptance test &T

1680 50 K JM 001 Page: 71
3.9 Single Test Trial For Area 08 – Primary Gas Catcher (PDC
Area)
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
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:

1680 50 K JM 001 Page: 72
For Commissioning protocols, see dedicated manual of Steam Bleeder valve.
Steam bleeder v Precondition

alve
□ Industrial water □ N2
Check list
□ Check the mechanical rigging See Vendor catalo
gues for Installation
□ Check instrumentation and check
□ Check industrial water system
□ Check wast water system
□ Check N2 line
Tests
□ Cold Test
Cooling pipes Precondition
□ Mechanical □ Cooling water
□ Instruments
Check list
See Drawing and
□ Check the mechanical rigging P&ID
Tests
□ Cold Test
PDC instrument Precondition
ation and
HT EJ □ Power □Mechanical
Check list
See THERMAX Ex
□ Check the mechanical rigging pansion drawing an
□ Check Installation position instrumentati d EJ vendor techni
on cal instructions
□ Check Installation drawings and cold di
splacement
Tests
□ Simulation testing

1680 50 K JM 001 Page: 73
3.10 Single Test Trial For Area 09 – Boiler Circuit (Boiler Area)
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 53 G01 001 HRSG flow diagram CDQ 10

1680 53 G01 002 H&M balance (PG condition) - CDQ 10
1680 53 G01 101 HRSG flow diagram CDQ 11
1680 53 G01 102 H&M balance (PG Condition) - CDQ 11
1680 53 G02 001 P&ID for WHB CDQ and Steam Drum CDQ 10
P&ID for De-aerator, BFW Pump station and sub Economizer system C
1680 53 G02 002 DQ 10
1680 53 G02 003 P&ID for Dosing System CDQ 10
1680 53 G02 004 Swas P&ID CDQ 10
1680 53 G02 101 P&ID for WHB CDQ and Steam Drum CDQ 11
P&ID for De-aerator, BFW Pump station and sub Economizer system C
1680 53 G02 102 DQ11
1680 53 G02 103 P&ID for Dosing System CDQ 11
1680 53 G02 104 Swas P&ID CDQ 11
1680 53 G11 001 Boiler and drum - General arrangement CDQ 10
1680 53 G11 002 Sub economizer - General arrangement CDQ 10
1680 53 G11 003 De-aerator - General arrangement CDQ 10
1680 53 G11 004 Layout of boiler auxiliaries equipment for CDQ 10
1680 53 G11 006 SWAS - General arrangement CDQ 10
1680 53 G11 101 Boiler and drum - General arrangement CDQ 11
1680 53 G11 102 Sub economizer - General arrangement CDQ 11
1680 53 G11 103 De-aerator - General arrangement CDQ 11
1680 53 G11 104 Layout of boiler auxiliaries equipment for CDQ 11
1680 53 G11 106 SWAS - General arrangement CDQ 11
1680 53 G11 200 Boiler and drum - General arrangement for pressure parts - CDQ 10
1680 53 G11 201 Boiler and drum - General arrangement for pressure parts - CDQ 11
1680 53 G11 210 Boiler - General Arrangement of Wear protection lining - CDQ 10&11

1680 50 K JM 001 Page: 74
For Boiler Technical data refer to the following documents:

§ Boiler O&M manual (here attached) : 168053GM2001-101
§ Boiler Datasheet 168053GDS001-101
For Commissioning protocols, see dedicated commissioning Manual of Boiler 168053GM3001-

101.
The following table include a general purpose list of checks to be executed and integrated with
Boiler Designer procedure.
Bar pump Precondition

house
□ Power □ Mechanical
□ Instrumentation
□ Cooling water □ Pumps □ fire extingui
shing system
Check list
According the method descri
□ Check the mechanical rigging bed in "HRSG commissionin
□ Check instrumentation 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
Tests
□ Test run of pumps
Acceptance procedure by TH
□ Acceptance test ERMAX

1680 50 K JM 001 Page: 75
Boiler Precondition
□ Instrumentation
□ N2 □ I/O connected □ Auxiliaries
□ Insulation and cladding
Check list
□ Check the mechanical rigging According the method descri
bed in "HRSG commissionin
g manual" №G1680 53 G M
□ Check the N2 line 3 001 by Thermax Ltd
□ Check piping lines
□ Check control power system
□ Check control valves
Tests
□ Hydraulic test
□ IBR Inspector Hydraulic test
□ Acceptance test Thermax
Deaerator Precondition
□ Mechanical □ Pipes system
□ Instrumentation
□ Water □ LP Steam
Check list
According the method descri
□ Check pipes line g manual" №G1680 53 G M
□ Check water system
□ Check steam system
Tests
□ Hydraulic test
□ Acceptance test Thermax
Sub - economi Precondition
zer
□ Mechanical □ Instrumentation
Check list According the method descri
□ Check instrumentation g manual" №G1680 53 G M
Tests
□ Hydraulic test
□ Gas density test

1680 50 K JM 001 Page: 76
3.11Single Test Trial For Area 10 – Cooling Gas Circuit
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
3.11.3 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

1680 50 K JM 001 Page: 77
For Commissioning protocols, see dedicated commissioning of equipment.
Multicyclone Precondition
□ Mechanical □ Instrumentation □ N2
Check list
□ Check the mechanical rigging See MCY Manual install
ation and Instrumentation
□ Check instrumentation TDS
Tests
□ Gas density test / pressure Drop
Gas circulation f Precondition
an
□ Instrumentation
□ N2 □ Cooling water
Check list
According the method d
□ Check power supply system escribed in "Insruction m
□ Check the mechanical rigging anual for Gas circulation
□ Check instrumentation fan" №fan manual/howd
en2015 by Howden Ltd
Tests
□ Test run of GCF
□ Cold Test
Acceptance procedure b
□ Acceptance test y customer
Lower bleeder li Precondition
ne
□ Instrumentation
□ Compressed air □ Coke oven gas
Check list
□ Check power supply system See Valve TDS and Inst
□ Check the mechanical rigging rumentation TDS
□ Check compressed air system
□ Check coke oven gas line
Tests
□ Cold Test

1680 50 K JM 001 Page: 78
Emergency blee Precondition

der
Check list
□ Check the mechanical rigging See Flare Manual
Tests
LOUVER DAMP Precondition
ER
Check list
See LOUVER DAMPER
□ Check the mechanical rigging Manual
Tests

1680 50 K JM 001 Page: 79
3.12Single Test Trial For Area 11 – Coke Breeze Circuit Area
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
3.12.3 Rotary Valves RSV541001-02-03-04 -05 (CDQ 10) and RSV541101-02-03-04-

05 (CDQ 11)
3.12.4 Chain conveyors & BE
Capacity: 5 tph working (6 tph maximum)

See TDS for details

1680 50 K JM 001 Page: 80
Chain conveyors Precondition

circuit
Check list
See Chain conveyor, R
□ Check the mechanical rigging SV, gate manuals
□ Check conveyors instrumentation
Tests
□ Test run of chain conveyors
□ Cold Test
Precondition
Check list
Bucket Elevator □ Check the mechanical rigging See BE Manual
Tests
□ Test run of BE
□ Cold Test
Coke breeze bin Precondition
and unloading sy
stem □ Power □ Mechanical □ Instrumentation
□ N2 □ Industrial water
Check list
□ Check the mechanical rigging See Vendor manuals
□ Check the industrial water system
Tests
□ Cold Test

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)
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
Refer to 1680 54 G A0 001-002 – PFD for DE units

3.13.3 Bag Filter

1680 50 K JM 001 Page: 82
3.13.4 DE FAN
ID Fan Precondition
□ Instrumentation
□ Cooling water □ Oil lubricated system
According the method
Check list described in "Erection
□ Check power supply system operationg and maint
□ Check the mechanical rigging enance manual for ce
ntrifugal fan" by Andre
□ Check instrumentation w Yule and Company
□ Check cooling water system limited
□ Check oil lubricated system
Tests
□ Test run of Id fan
□ Cold Test
Acceptance procedure
□ Acceptance test by L&T
Dedusting chargi Precondition
ng system
□ Compressed air
Check list
□ Check the mechanical rigging Valve TDS and FD
Tests

1680 50 K JM 001 Page: 83
Regulation of ho Precondition
ods
□ Mechanical □ Control system According the method
Check list described in "Erection
□ Check the mechanical rigging operationg and maint
enance manual for ce
□ Check the control system ntrifugal fan" by Andre
Tests w Yule and Company
limited
□ Cold test
Bag filter unit Precondition
□ Instrumentation
□ Instrumentation air □ Compressed air
□ N2
Check list
According in the P &
□ Check power supply system ID bag filter system
□ Check the mechanical rigging №O15044-0F2-M-V-01
□ Check instrumentation 51-001
□ Check instrumentation air system
Tests
□ Cold test
Chain conveyors Precondition
circuit
Check list
See Chain conveyor,
□ Check the mechanical rigging RSV, gate manuals
□ Check conveyors instrumentation
Tests
□ Test run of chain conveyors
□ Cold Test
Coke breeze bin Precondition
and unloading
system □ Power □ Mechanical □ Instrumentation
□ N2 □ Industrial water
Check list
□ Check the mechanical rigging See Vendor manuals
□ Check the industrial water system
Tests
□ Cold Test

1680 50 K JM 001 Page: 84
3.14 Single Test Trial For Area 13 – Maintenance equipment (H

oists) & Others
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.

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 Hydraulic Inertization PAT

LINE / FLUID Pressure test
test
Process Lines:
CDQ Gas circuit O
X X (3kPa) n.a. X
(rusting)
Dilution Air line O
X X (10kPa) n.a. (1)
(rusting)
Lower bleeding line O
X X (3kPa) n.a. (1)
(rusting)
Dedusting Line O Negative
(rusting) n.a. pressure n.a. -
line
Utilities Lines:
Instrument Air X X X
Compressed Air X X X
Nitrogen X X X
COG X X X X
Clarified Industrial X
X X
Water
Drinking Water X X X
Waste Water O
X O
(rusting)
Utilities Lines (IBR):
Demi Water X See TL
IBR
/L&T loops
LP Steam X See
IBR
Thermax
HP Steam Steam See
IBR
Blowing X Thermax
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

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.

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

1680 50 K JM 001 Page: 88

1680 50 K JM 001 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
§ 168080U02015 Loops 1 – 2 – 3
§ 168050K02002 Loop 2
4.4.2 Compressed Air
§ 168080U02015 Loops 1 – 2 – 3 – 4 – 5
4.4.3 Nitrogen
§ ESA-80-013- CDQ 11 loop1 Nitrogen

1680 50 K JM 001 Page: 91

§ 168080U02013 Loops 1 – 2 – 3 – 4 – 5 – 6
4.4.4 COG
§ ESA-80-019-CDQ 11 COG END OF ERECTION
§ 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.

COMMESSA / JOB
G1680 – TATA – INDIA –
PRELIMINARY DATA / DATE
____________________
CDQ COB 10 -11 ACCEPTANCE TEST
MANUAL N. DOCUMENT NUMBER TEST TYPE
168050KJM001 ESA/80/015-CDQ11 END OF ERECTION
DWGS N. EQUIPMENT: SUPPLIER:
PW Drawing number CDQ – 11 Instrument air L&T

L&T Drawings number
(to be listed here)
GENERAL P&I .
1680 80 U 02 015 – CDQ 11
1680 50 K 02 004 – CDQ 11
1680 50 K 02 006 – CDQ 11
ESEGUITO/ DATA / COMMENTI

POS DESCRIZIONE DELL’ATTIVITA’/ DESCRIPTION OF ACTIVITIES
EXECUTED 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
____________________

10BA09-8011-AI-0015-N-247
10BA09-8011-AI-0015-N-230
Cleaning of line and control absence of dirt inside

1 YES NO
the line
Check the installation and connection of the line

2 YES NO
LINE FLUSHING WITH COMPRESSED AIR

Acting from great diameters to small diameters
flux lines utilizing compressed air.
3 YES NO
Before flushing, all instruments must be
disconnected
Remove all dirt at end
Hydraulic test of line BEFORE PAINTING

utilizing dried compressed air..
MOP = 6 bar
Pressure 5.5-6 bar.
4 YES NO
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.
Control circuit leakage. In case of fail of test (4)

4a check with soap/water mix leakage point. Repair YES NO
and test again as per point (4)
5 Control of the correct erection YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

6 Control instrumentation installed on lines YES NO
7 Control execution superficial treatment of lines YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________
168050KJM001 ESA/80/015-CDQ11 – Loop1 END OF ERECTION
PW Drawing number CDQ11 – Instrument air L&T

L&T Drawings number
(to be listed here) Loop 1
GENERAL P&I .
1680 80 U 02 015 – CDQ 11
1680 50 K 02 002 – CDQ11

MAIN LINE TAG

10BA09-8011-AI-0065-N-239

1 YES NO
the line

2 10BA09-8011-AI-0065-N-239 YES NO
According to P&ID 168080U02015

3 YES NO
disconnected
Close valves BAL1166NB25, (GL1073NB32,

GL1074NB32, GL1067NB32, GL1071NB32
according P&ID 1680 50 K 02 002)
BAL1022NB50, BAL1024NB25, BAL1025NB25,
3a BAL1295NB25, BAL1167NB25, BAL1168NB25, YES NO
BAL1066NB15, BAL1162NB15, BAL1061NB25

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

COMMESSA / JOB
____________________

Disconnect end cup/flange on line 10BA09-8011-

3b YES NO
AI-0065-N-239 termination
Open valve BAL1243NB65 and flushing with

3c compressed air line10BA09-8011-AI-0065-N- YES NO
239, then close valve.
Close end cup/blanked on line 10BA09-8011-AI-

3d YES NO
0065-N-239
Pneumatic test of line BEFORE PAINTING

utilizing with compressed air.
MOP = 6 bar
Pressure 5,5-6 bar.
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 2

COMMESSA / JOB
____________________
168050KJM001 ESA/80/015-CDQ11 – Loop 2 END OF ERECTION

L&T Drawings number
GENERAL P&I .
1680 80 U 02 015 – CDQ 11
1680 50 K 02 002 – CDQ11

MAIN LINE TAG

10BA09-8011-AI-0050-N-241
10BA09-8011-AI-0032-N-248

1 YES NO
the line

10BA09-8011-AI-0050-N-241
2 YES NO
10BA09-8011-AI-0032-N-248

3 YES NO
disconnected
Close valves BAL1166NB25, BAL1024NB25,


________________ ________________ ________________
GENERAL NOTES
PAG 1 / 3

COMMESSA / JOB
____________________

BAL1061NB25
3b Open valve BAL1243NB65 YES NO
Open valve BAL1022NB50, BAL1023NB50 and

3c flushing line10BA09-8011-AI-0050-N-241, then YES NO
close valve.
Remove PCV1070NB32, PCV1066NB32 valves

3d YES NO
and install adapter pipe on this place
Valves GL1073NB32, GL1074NB32,

3e BAL1271NB32, BAL1268NB32 (according P&ID YES NO
1680 50 K 02 002) must be closed
Open valve GL1067NB32 and flushing line in to

3f YES NO
pre chamber, then close valve
Open valve GL1071NB32 and flushing line in to

3g YES NO
pre chamber, then close valve
Remove adapter pipe and install

3h PCV1070NB32, PCV1066NB32 valves on this YES NO
place

MOP = 6 bar
Pressure 5,5-6 bar.
4 YES NO
be noted.
4a Control circuit leakage. In case of fail of test (4) YES NO

check with soap/water mix leakage point. Repair

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 015 – CDQ 11
1680 50 K 02 002 – CDQ11

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

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 5

COMMESSA / JOB
____________________


1 YES NO
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
10BA09-8011-AI-0025-N-234
2 YES NO
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

3 YES NO
disconnected

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 5

COMMESSA / JOB
____________________

Close valves GL1073NB32, GL1074NB32,

3a GL1067NB32, GL1071NB32 according P&ID YES NO
1680 50 K 02 002, BAL1022NB50,
Open valve BAL1166NB25, then in sequence

open valves from BAL1170NB15 to
3b YES NO
BAL1174NB15 and flushing line 10BA09-8011-
AI-0025-N-233, then close valve BAL1166NB25

3c YES NO

3d YES NO

3e YES NO

3f YES NO

3g YES NO

3h YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 5

COMMESSA / JOB
____________________


3i YES NO

3j YES NO
Open valve BAL1175NB25, and flushing line

3k 10BA09-8011-AI-0025-N-231, then close valve YES NO
BAL1175NB25
Open valve BAL1176NB25 and flushing line

3l 10BA09-8011-AI-0025-N-249, then close valve YES NO
BAL1176NB25

3m 10BA09-8011-AI-0015-N-242, then close valve YES NO
BAL1027NB15

3n 10BA09-8011-AI-0015-N-244, then close valve YES NO
BAL1035NB15

3o 10BA09-8011-AI-0015-N-245, then close valve YES NO
BAL1045NB15

3p 10BA09-8011-AI-0015-N-246, then close valve YES NO
BAL1046NB15

3q 10BA09-8011-AI-0015-N-240, then close valve YES NO
BAL1066NB15
3r Open valve BAL1062NB15, and flushing line YES NO

10BA09-8011-AI-0015-N-247, then close valve

________________ ________________ ________________
GENERAL NOTES
PAG 4 / 5

COMMESSA / JOB
____________________

BAL1062NB15

3s 10BA09-8011-AI-0025-N-230, then close valve YES NO
BAL1061NB25
Open valve BAL1295NB25, BAL0296NB and

flushing line 10BA09-8011-AI-0025-N-
3t YES NO
250,10BA09-8000-AI-0025-N-342 then close
valve BAL1295NB25

MOP = 6 bar
Pressure 5,5-6 bar.
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 5 / 5

BAL1170
NB15
DRAIN
BAL1171
NB15
SPARE
BAL1172
NB15
SPARE
BAL1173
NB15
SPARE 10BA09-8011-AI-0025-N-233
BAL1174
NB15
50x15
BAL1182
10BA09-8011-AI-0050-N-241
NB15
Open/close
SOV541180
BAL1181
NB15
SPARE
BAL1177
NB15
SPARE BAL1183
PV511101 NB15
SPARE
Closed
BAL1178 BAL1184
NB15 NB15
SPARE
EBV541101
BAL1179 BAL1185
NB15 NB15
SPARE
EBV541102 BAL1186
BAL1180 NB15 SOV541003
BAL1188 NB15
NB25
SOV511101
SOV511110.01
BAL1189 SOV511110.02
NB15 BAL1190 BAL1194
NB15
SPARE
NB15
SOV511109 BAL1195
BAL1191 NB15
FV801116
NB15
LV801119 BAL1196
NB15
SPARE
BAL1192
NB15 BAL1197
*
BAL1199 SOV511181 NB15 SPARE
BAL1193
NB15
NB15 10BA09-8011-AI-0025-N-238
SOV511180 *
FV511150
BAL1200 SPARE BAL1205
NB15 BAL1201 SOV511150.1 10BA09-8011-AI-0025-N-237
NB15
NB15 BAL1206
SOV511132 NB15
SPARE *
BAL1202
NB15 BAL1207
SOV561101 SOV801105.01 10BA09-8011-AI-0025-N-236
NB15
BAL1203
NB15 BAL1208
NB15
SOV801105.02
SPARE
BAL1204 BAL1214
NB15
SOV541181 SOV510092
BAL1210 NB15 **
Closed
NB15 BAL1215
*
SPARE SOV510090.01 **
NB15
BAL1211 BAL1216
NB15 FV510091.01 ** 10BA09-8011-AI-0025-N-243
NB15
SOV521182 BAL1217
BAL1212 SOV801005.01 **
NB15
SOV521181 NB15 DRAIN
BAL1222 BAL1218
BAL1213 SOV511183 SPARE
BAL1219 NB15 NB15
NB15
NB15 BAL1223
*
NB15 SPARE
DRAIN
BAL1221 BAL1224 10BA09-8011-AI-0025-N-235
NB15 NB15
SPARE
SOV511182 BAL1225
BAL1220 NB15 SPARE
NB15
BAL1229
BAL1226 SPARE
NB15
*
NB15
DRAIN
BAL1228 BAL1230 10BA09-8011-AI-0025-N-232
NB15 NB15
SPARE
BAL1227
NB15
BAL1233
NB15 SPARE
*
BAL1231
NB15
BAL1234 10BA09-8011-AI-0025-N-234
DRAIN NB15 SPARE
BAL1232 BAL1235
NB15 NB15
SPARE
Closed
*
10BA09-8011-AI-0025-N-231
* 10BA09-8011-AI-0025-N-231
10BA09-8011-AI-0025-N-249
*
10BA09-8011-AI-0015-N-242
*
10BA09-8011-AI-0015-N-244
Closed
*
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-0025-N-230
Disconnect/connect
BAL1170
NB15
DRAIN
BAL1171
NB15
SPARE
BAL1172
NB15
SPARE
BAL1173
NB15
SPARE 10BA09-8011-AI-0025-N-233
BAL1174
NB15
Open/close
50x15
BAL1182
10BA09-8011-AI-0050-N-241
NB15
SOV541180
BAL1181
NB15
SPARE
BAL1177
NB15
SPARE BAL1183
PV511101 NB15
SPARE
Closed
BAL1178 BAL1184
NB15 NB15
SPARE
EBV541101
BAL1179 BAL1185
NB15 NB15
SPARE
EBV541102 BAL1186
BAL1180 NB15 SOV541003
BAL1188 NB15
NB25
SOV511101
SOV511110.01
BAL1189 SOV511110.02
NB15
SPARE
NB15
SOV511109 BAL1195
BAL1191 NB15
FV801116
NB15
LV801119 BAL1196
NB15
SPARE
BAL1192
NB15 BAL1197
*
BAL1193
NB15
NB15 10BA09-8011-AI-0025-N-238
SOV511180 *
FV511150
NB15 BAL1201 SOV511150.1 10BA09-8011-AI-0025-N-237
NB15
NB15 BAL1206
SOV511132 NB15
SPARE *
BAL1202
NB15
Open/close
BAL1207 10BA09-8011-AI-0025-N-236
SOV561101 NB15 SOV801105.01
BAL1203
NB15 BAL1208
NB15
SOV801105.02
SPARE
BAL1204 BAL1214
NB15
SOV541181 SOV510092
BAL1210 NB15 **
Closed
NB15 BAL1215
*
SPARE SOV510090.01 **
NB15
BAL1211 BAL1216
NB15 FV510091.01 ** 10BA09-8011-AI-0025-N-243
NB15
SOV521182 BAL1217
BAL1212 SOV801005.01 **
NB15
BAL1222 BAL1218
BAL1219 NB15 NB15
NB15
NB15 BAL1223
*
NB15 SPARE
DRAIN
BAL1221 BAL1224 10BA09-8011-AI-0025-N-235
NB15 NB15
SPARE
SOV511182 BAL1225
BAL1220 NB15 SPARE
NB15
BAL1229
BAL1226 SPARE
NB15
*
NB15
DRAIN
BAL1228 BAL1230 10BA09-8011-AI-0025-N-232
NB15 NB15
SPARE
BAL1227
NB15
BAL1233
NB15 SPARE
*
BAL1231
NB15
BAL1234 10BA09-8011-AI-0025-N-234
DRAIN NB15 SPARE
BAL1232 BAL1235
NB15 NB15
SPARE
Closed
*
10BA09-8011-AI-0025-N-231
* 10BA09-8011-AI-0025-N-231
10BA09-8011-AI-0025-N-249
*
10BA09-8011-AI-0015-N-242
*
10BA09-8011-AI-0015-N-244
Closed
*
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-0025-N-230
BAL1170
NB15
DRAIN
BAL1171
NB15
SPARE
BAL1172
NB15
SPARE
BAL1173
NB15
SPARE 10BA09-8011-AI-0025-N-233
BAL1174
NB15
50x15
BAL1182
10BA09-8011-AI-0050-N-241
NB15
SOV541180
BAL1181
NB15
SPARE
BAL1177
NB15
SPARE BAL1183
PV511101 NB15
SPARE
BAL1178 BAL1184
NB15 NB15
SPARE
EBV541101
BAL1179 BAL1185
NB15 NB15
SPARE
EBV541102 BAL1186
BAL1180 NB15 SOV541003
BAL1188 NB15
NB25
SOV511101
SOV511110.01
BAL1189 SOV511110.02
NB15
SPARE
NB15
SOV511109 BAL1195
BAL1191 NB15
FV801116
NB15
LV801119 BAL1196
NB15
SPARE
BAL1192
NB15 BAL1197
*
BAL1193
NB15
NB15 10BA09-8011-AI-0025-N-238
SOV511180 *
FV511150
NB15 BAL1201 SOV511150.1 10BA09-8011-AI-0025-N-237
NB15
NB15 BAL1206
SOV511132 NB15
SPARE *
BAL1202
NB15 BAL1207
SOV561101 SOV801105.01 10BA09-8011-AI-0025-N-236
NB15
BAL1203
NB15 BAL1208
NB15
SOV801105.02
SPARE
BAL1204 BAL1214
NB15
SOV541181 SOV510092
BAL1210 NB15 **
NB15 BAL1215
*
SPARE SOV510090.01 **
NB15
BAL1211 BAL1216
NB15 FV510091.01 ** 10BA09-8011-AI-0025-N-243
NB15
SOV521182 BAL1217
BAL1212 SOV801005.01 **
NB15
BAL1222 BAL1218
BAL1219 NB15 NB15
NB15
NB15 BAL1223
*
NB15 SPARE
DRAIN
BAL1221 BAL1224 10BA09-8011-AI-0025-N-235
NB15 NB15
SPARE
SOV511182 BAL1225
BAL1220 NB15 SPARE
NB15
BAL1229
BAL1226 SPARE
NB15
*
NB15
DRAIN
BAL1228 BAL1230 10BA09-8011-AI-0025-N-232
NB15 NB15
SPARE
BAL1227
NB15
BAL1233
NB15 SPARE
*
BAL1231
NB15
BAL1234 10BA09-8011-AI-0025-N-234
DRAIN NB15 SPARE
BAL1232 BAL1235
NB15 NB15
SPARE
*
10BA09-8011-AI-0025-N-231
* 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-0025-N-230
50x20 65x50
10BA04-8011-WF-0065-N-177
TO LIT 511101
ELECTRONICS
TO LIT 511102
ELECTRONICS
closed
10BA04-8011-NI-0080-N-196 10BA04-8011-AP-0040-N-251
Open/close
Remove PCV and
install adapter pipe
Closed
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
COMMESSA / JOB
____________________
PW Drawing number CDQ – 11 Compressed air L&T

L&T Drawings number
(to be listed here)
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

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 YES NO
the line
2 Control lines gradient, vent installation. YES NO

Acting from small diameters to greater diameters
3 YES NO

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

COMMESSA / JOB
____________________


MOP = 6 bar
Pressure 5-6 bar.
4 YES NO
Close all connections. Inflate dried compressed
air in order to reach test pressure, to be checked
with record of pressure and temperature.
be noted.


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

COMMESSA / JOB
____________________
PW Drawing number CDQ11 – Compressed air L&T

L&T Drawings number
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

MAIN LINE TAG

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

1 YES NO
the line

10BA04-8011-AP-0050-N-273
2 10BA04-8011-AP-0015-N-275 YES NO
10BA04-8000-AP-0015-N-351

3 YES NO


3b YES NO
AP-0050-N-273 termination

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

COMMESSA / JOB
____________________


3c compressed air line10BA04-8011-AP-0050-N- YES NO
273, then close valve.
Close end cup/blanked on line 10BA04-8011-AP-

3d YES NO
0050-N-273
Open valves BAL1236NB50, BAL1164NB15 and

flushing with compressed air lines 10BA04-8011-
3e YES NO
AP-0015-N-275, 10BA04-8000-AP-0015-N-351,
then close valve
Close valves BAL 1236NB50, BAL1164NB15

3f YES NO
stop flushing.

MOP = 6 bar
Pressure 5-6 bar.
4 YES NO
Close all connections. Inflate dry compressed air
in order to reach test pressure, to be checked
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

MAIN LINE TAG

10BA04-8011-AP-0025-N-269

1 YES NO
the line

2 10BA04-8011-NI-0025-N-269 YES NO

3 YES NO

BAL1033NB40,BAL1020NB40

3c 10BA04-8011-AP-0025-N-269. YES NO
Then close valve.

4 YES NO
utilizing compressed air.

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 2

COMMESSA / JOB
____________________

MOP = 6 bar
Pressure 5-6 bar.
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 2

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

MAIN LINE TAG

10BA04-8011-AP-0040-N-251
10BA04-8011-AP-0040-N-252

1 YES NO
the line

10BA04-8011-AP-0040-N-251
2 YES NO
10BA04-8011-AP-0040-N-252

3 YES NO

BAL1020NB40

3c 10BA04-8011-AP-0040-N-251. YES NO
Then close valve.

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

COMMESSA / JOB
____________________

Valve BAL1031NB40 must be closed

3d 10BA04-8011-AP-0040-N-252. YES NO
Then close valve.

MOP = 6 bar
Pressure 5-6 bar.
4 YES NO
be noted.


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

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

MAIN LINE TAG

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

1 YES NO
the line

2 10BA04-8011-AP-0040-N-272 YES NO

3 YES NO

3a BAL1030NB40, BAL1031NB40, BAL1164NB15 YES NO
BAL1033NB40, BAL1020NB40
3c Open valve BAL1236NB50 YES NO

compressed air line 10BA04-8011-AP-0040-N-
3e 272 YES NO
Then close valve

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

COMMESSA / JOB
____________________

3f Close valve BAL 1236NB50 stop flushing. YES NO

MOP = 6 bar
Pressure 5-6 bar.
4 YES NO
be noted.


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

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 016 – CDQ 11

MAIN LINE TAG

10BA04-8011-AP-0040-N-274
10BA04-8011-AP-0080-N-253

1 YES NO
the line

10BA04-8011-AP-0040-N-274
2 YES NO
10BA04-8011-AP-0080-N-253

3 YES NO

BAL1032NB40, BAL0340NB15.
Dismantle Reducing pressure valves

PCV1025NB40, PCV1026NB40 and install
3b adapter pipe. YES NO
Install these valves after completion Loop 5

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

COMMESSA / JOB
____________________

Disconnect a flange before the valve

3c YES NO
GV1002NB80
3d Open valve BAL1236NB50 YES NO

10BA04-8011-AP-0040-N-274.
3e YES NO
Then close valve.

3f 10BA04-8011-AP-0080-N-253. YES NO
Then close valve.
3g Connect flange before valve GV1002NB80. YES NO

MOP = 0.2 bar
Pressure 0.1-0.2 bar.
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

Closed Close/Open
Closed
Disconnect/connect
Closed Closed
Closed
Closed
10BA04-8011-AP-0040-N-272
50x40
Closed Closed
80x40
80x40
Closed Closed
Closed
Closed
Closed
Open/Close Open/Close
10BA04-8011-AP-0040-N-272
50x40
80x40
80x40
Closed
Closed
Closed
Closed
Closed
Closed
Open/Close Closed
10BA04-8011-AP-0040-N-272
50x40
80x40
80x40
Open/Close
Closed
Closed
Closed
Open/Close Open/Close Closed
Closed
10BA04-8011-AP-0040-N-272
50x40
80x40
80x40
Closed
Closed
Closed
Closed
Open/Close
Open/Close Closed Closed
10BA04-8011-AP-0040-N-272
50x40
Dismantle and install adapter pipe.
80x40
80x40
Closed Disconnect flange/connect
Closed
COMMESSA / JOB
____________________
PW Drawing number CDQ – 11 Nitrogen line L&T

L&T Drawings number
(to be listed here)
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

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

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

COMMESSA / JOB
____________________

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 YES NO
the line
2 Control lines gradient, vent installation. YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 4

COMMESSA / JOB
____________________


Acting from small diameters to greater diameters
3 YES NO

MOP = 8 bar
Pressure 7-8 bar.
4 YES NO
Close all connections. Inflate dried compressed
air in order to reach test pressure, to be checked
be noted.

Control of the correct erection of Expansion

5 YES NO
Joints

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 4

COMMESSA / JOB
____________________

8 Control execution thermal protection of the lines YES NO

where necessary (insulating thk and type)

________________ ________________ ________________
GENERAL NOTES
PAG 4 / 4

COMMESSA / JOB
____________________
PW Drawing number CDQ11 – Nitrogen line L&T

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

MAIN LINE TAG

10BA04-8011-NI-0100-N-212

1 YES NO
the line

2 10BA04-8011-NI-0100-N-212 According to P&ID YES NO
168080U02013
LINE FLUSHING WITH COMPRESSED

AIR/NITROGEN
3 Acting from great diameters to small diameters YES NO
flux lines utilizing compressed air/nitrogen.

BAL1008NB40, GV1005NB80, GV1013NB80,
GV1014NB100

3b YES NO
NI-0100-N-212 termination

3c YES NO
compressed air/nitrogen

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

COMMESSA / JOB
____________________

3d Close valve BAL 0384NB100, stop flushing. YES NO
Close end cup/blanked on line 10BA04-8011-NI-

3e YES NO
0100-N-212

utilizing nitrogen..
MOP = 8 bar
Pressure 7-8 bar.
4 YES NO
Close all connections. Inflate dry nitrogen in
be noted.



________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

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 YES NO
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 YES NO
10BA04-8011-NI-0040-N-203
10BA04-8011-NI-0080-N-201
10BA04-8011-NI-0025-N-214
10BA04-8011-NI-0100-N-199

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 4

COMMESSA / JOB
____________________


AIR/NITROGEN

3a YES NO
GV1005NB80, BAL1006NB40, BAL108NB40

3c 10BA04-8011-NI-0040-N-197. YES NO
Then close valve.

3d 10BA04-8011-NI-0025-N-192. YES NO
Then close valve.

10BA04-8011-NI-0040-N-225, 10BA04-8000-NI-
3e 0040-N-341. YES NO
Then close valve.

3f 10BA04-8011-NI-0040-N-203. YES NO
Then close valve.
Open valve GV1013NB80 and flushing line

3g 10BA04-8011-NI-0080-N-201. YES NO
Then close valve

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 4

COMMESSA / JOB
____________________


3h YES NO

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 YES NO
Open valve BAL1017NB25
Then alternately open and close the valve from
BAL0356NB15 to BAL0405NB15
Close valve BAL1017NB25
Connect all instruments on this line.

3j 10BA04-8011-NI-0100-N-199. YES NO
Then close valve.

MOP = 8 bar
Pressure 7-8 bar.
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 4

COMMESSA / JOB
____________________


COMMISSIONING
8 Line Inertizing according to procedure YES NO

INERT- _________(only for nitrogen line
10BA04-8000-NI-0040-N-341)

________________ ________________ ________________
GENERAL NOTES
PAG 4 / 4

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

MAIN LINE TAG

10BA04-8011-NI-0150-N-209
10BA04-8011-NI-0040-N-224
10BA04-8011-NI-0065-N-222

1 YES NO
the line

10BA04-8011-NI-0150-N-209
2 10BA04-8011-NI-0040-N-224 YES NO
10BA04-8011-NI-0065-N-222

AIR/NITROGEN

BAL\1017NB25, GV1014NB100, GV1013NB80,
GV1005NB80, BAL1160NB40, BAL1081NB40,
3a YES NO
BAL1006NB40, BAL1008NB40, GV1012NB100,
BAL1097NB25, GV1020NB80, BAL1083NB50,

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 3

COMMESSA / JOB
____________________


PCV1001NB50, PCV1002NB50 and install
3b adapter pipe. YES NO
Install these valves after completion Loop 4

3c NI-0150-N-209 and end on line 10BA04-8011-NI- YES NO
0040-N-224 termination
Disconnect a flange before the valve

3d YES NO
GV1009NB150
3e Open valve BAL0384NB100 YES NO

10BA04-8011-NI-0150-N-209.
3f YES NO
Then close valve.

3g 10BA04-8011-NI-0065-N-222. YES NO
Then close valve.
Connect flange before valve GV1009NB150.

3h Connect end cup/flange on line 10BA04-8011-NI- YES NO
0150-N-209 and end on line 10BA04-8011-NI-

utilizing nitrogen.
MOP = 0.2 bar
4 Pressure 0.1-0.2 bar. YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

be noted.



________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 10

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 YES NO
the line

10BA04-8011-NI-0065-N-215
10BA04-8011-NI-0025-N-353
10BA04-8011-NI-0100-N-213
2 YES NO
10BA04-8011-NI-0100-N-223
10BA04-8011-NI-0025-N-205
10BA04-8011-NI-0080-N-196
10BA04-8011-NI-0050-N-211

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 4

COMMESSA / JOB
____________________

10BA04-8011-NI-0025-N-198
10BA04-8011-NI-0025-N-193

AIR/NITROGEN

BAL1017NB25, GV1014NB100, GV1013NB80,
3a YES NO
GV1005NB80, BAL1160NB40, BAL1081NB40,

3b PCV1001NB50, PCV1002NB50 and install YES NO
adapter pipe.
3c Open valve BAL0384NB100 YES NO
3d Open valve BAL1015NB50 YES NO

3e 10BA04-8011-NI-0065-N-215 . YES NO
Then close valve

3f 10BA04-8011-NI-0025-N-353. YES NO
Then close valve.
Open valve GV1012NB100, GV1063NB100,

GV1064NB100 and flushing line 10BA04-8011-
3g NI-0100-N-213, 10BA04-8011-NI-0100-N-223. YES NO
Then close valves.

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 4

COMMESSA / JOB
____________________


3h 10BA04-8011-NI-0025-N-205. YES NO
Then close valve.

3i 10BA04-8011-NI-0080-N-196. YES NO
Then close valve.

3j 10BA04-8011-NI-0050-N-211. YES NO
Then close valve.

3k 10BA04-8011-NI-0025-N-198. YES NO
Then close valve.

3m 10BA04-8011-NI-0025-N-193. YES NO
Then close valve.
Install Reducing pressure valves PCV1001NB50,

3n YES NO
PCV1002NB50

MOP = 0.2 bar
Pressure 0.1- 0.2 bar.
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 4

COMMESSA / JOB
____________________



________________ ________________ ________________
GENERAL NOTES
PAG 4 / 4

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

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 YES NO
the line

10BA04-8011-NI-0080-N-220
10BA04-8011-NI-0040-N-207
2 10BA04-8011-NI-0040-N-200 YES NO
10BA04-8011-NI-0080-N-204
10BA04-8011-NI-0050-N-221

AIR/NITROGEN

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 4

COMMESSA / JOB
____________________


BAL1017NB25, GV1014NB100, GV1013NB80,
3a YES NO

3c YES NO

3b 10BA04-8011-NI-0080-N-220. YES NO
Then close valve.
Connect end cup/flange on line 10BA04-8011-NI-

3e YES NO
3f Open valve GV1005NB80 YES NO
Open valve BAL0381NB40 and flushing line to

3g COG PIPING LINE PURGING. YES NO
Then close valve.

3h 10BA04-8011-NI-0040-N-207. YES NO
Then close valve.

3i 10BA04-8011-NI-0080-N-204. YES NO
Then close valve.

3j 10BA04-8011-NI-0050-N-221. YES NO
Then close valve.

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 4

COMMESSA / JOB
____________________


3k 10BA04-8011-NI-0040-N-200. YES NO
Then close valve.

MOP = 8 bar
Pressure 7-8 bar.
4 YES NO
be noted.



________________ ________________ ________________
GENERAL NOTES
PAG 3 / 4

COMMESSA / JOB
____________________

________________ ________________ ________________
GENERAL NOTES
PAG 4 / 4

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 013 – CDQ 11

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 YES NO
the line

2 10BA04-8011-NI-0040-N-210 YES NO
10BA04-8011-NI-0040-N-219

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

COMMESSA / JOB
____________________

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

AIR/NITROGEN

BAL1017NB25, GV1014NB100, GV1013NB80,
3a YES NO
BAL1018NB50, GV1005NB80

3b PCV1003NB40, PCV1004NB40 and install YES NO
adapter pipe.

3c NI-0040-N-210 and 10BA04-8011-NI- 0040-N- YES NO
218 termination

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 6

COMMESSA / JOB
____________________

3d Disconnect flange befor valve BAL1010NB50 YES NO
3e Disconnect all instrumentation (Gas analyzers) YES NO
3f Open valve BAL0384NB100 YES NO
Open valves BAL1006NB40 and BAL1009NB50

Valves BAL1008NB40, BAL1010NB50 and
BAL1073 must be Closed
Flushing line 10BA04-8011-NI-0040-N-210 about
3g 15 minutes YES NO
Then open valve BAL1008NB40 flushing line
10BA04-8011-NI-0040-N-219
Then close valves BAL1006NB40 and
BAL1008NB40

3h YES NO
3i Connect flange befor valve BAL1010NB50 YES NO
3j Open valve BAL1006NB40 YES NO

3k 10BA04-8011-NI-0032-N-195 YES NO
Then close valve.

3l 10BA04-8011-NI-0032-N-194. YES NO
Then close valve.
3m Open valves BAL1060NB40, BAL1242NB40 and YES NO

flushing lines 10BA04-8011-NI-0040-N-217,

________________ ________________ ________________
GENERAL NOTES
PAG 3 / 6

COMMESSA / JOB
____________________

10BA04-8011-NI-0040-N-216.
Then closed valves.

10BA04-8011-NI-0040-N-218.
Then close valve.
3n YES NO
Valves BAL1241NB20, BAL1051NB20,
BAL1240NB20, BAL1292NB20 must be closed.

3o YES NO
3p Open valve BAL1073NB40 YES NO

3q 10BA04-8011-NI-0020-N-295 YES NO
Then close valve.

3r 10BA04-8011-NI-0020-N-294 YES NO
Then close valve.

3s 10BA04-8011-NI-0020-N-293 YES NO
Then close valve.

3t 10BA04-8011-NI-0020-N-292 YES NO
Then close valve.

3u 10BA04-8011-NI-0020-N-291 YES NO
Then close valve.

________________ ________________ ________________
GENERAL NOTES
PAG 4 / 6

COMMESSA / JOB
____________________


3v 10BA04-8011-NI-0020-N-290 YES NO
Then close valve.

3w 10BA04-8010-NI-0020-N-591 YES NO
Then close valve.

3x YES NO
BAL1006NB40
3y Connect all instrumentation (Gas analyzers). YES NO
Install Reducing pressure valves PCV1003NB40,

3z YES NO
PCV1004NB40

MOP = 0.2 bar
4 YES NO
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 5 / 6

COMMESSA / JOB
____________________



________________ ________________ ________________
GENERAL NOTES
PAG 6 / 6

Closed
150x65
10BA04-8011-NI-0150-N-209 65X50
* *
Closed
150x65
65X50
* *
Closed
Closed
Closed
TO
Closed
Closed
FIT521104.01
BAL0405
NB15
TO
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
REMOVABLE PERMANENT
TO
FIT521104.02
Closed
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
Closed
TO
PDIT521110.01
BAL1151
NB15
TO
10BA04-8011-NI-0040-N-216 PIT521102
BAL1150
NB15
TO PIT541101
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
Closed
TO
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
10BA04-8010-NI-0020-N-294
10BA04-8010-NI-0020-N-293
Closed
Closed
10BA04-8010-NI-0020-N-292
10BA04-8010-NI-0020-N-291
10BA04-8010-NI-0020-N-290
Disconnect
10BA04-8010-NI-0020-N-591
Closed
150x65
10BA04-8011-NI-0150-N-209 65X50
* *
Open/Close
150x65
65X50
* *
Closed
Open/Close
Disconnect/connect
TO
FIT521104.01
Closed
BAL0405
NB15
TO
Open/Close
Open/Close
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
REMOVABLE PERMANENT
TO
FIT521104.02
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
TO
PDIT521110.01
BAL1151
Closed
Closed
NB15
TO
10BA04-8011-NI-0040-N-216 PIT521102
BAL1150
NB15
TO PIT541101
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
TO
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
10BA04-8010-NI-0020-N-294
Open/Close
Open/Close
10BA04-8010-NI-0020-N-293
10BA04-8010-NI-0020-N-292
Open/Close
10BA04-8010-NI-0020-N-291
10BA04-8010-NI-0020-N-290
10BA04-8010-NI-0020-N-591
Dismantle and install adapter pipe
150x65
Closed
10BA04-8011-NI-0150-N-209 65X50
* *
150x65
65X50
* *
Closed
Closed
Closed
Open/Close
Disconnect flange
TO
FIT521104.01
BAL0405
Closed
Closed
Closed
NB15
TO
Closed
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
REMOVABLE PERMANENT
TO
Closed
Closed
FIT521104.02
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
TO
PDIT521110.01
Closed
BAL1151
NB15
TO
Closed
10BA04-8011-NI-0040-N-216 PIT521102
BAL1150
NB15
TO PIT541101
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
TO
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
Closed
Closed
10BA04-8010-NI-0020-N-294
Closed
Closed
10BA04-8010-NI-0020-N-293
10BA04-8010-NI-0020-N-292
Disconnect/connect
10BA04-8010-NI-0020-N-291
10BA04-8010-NI-0020-N-290
10BA04-8010-NI-0020-N-591
150x65
Closed
10BA04-8011-NI-0150-N-209 65X50
* *
150x65
65X50
* *
Closed
Open/Close
Open/Close
TO
FIT521104.01
BAL0405
Closed
Closed
Closed
NB15
TO
Open/Close
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
Open/Close
Open/Close
REMOVABLE PERMANENT
TO
FIT521104.02
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
TO
PDIT521110.01
Closed
BAL1151
NB15
TO
10BA04-8011-NI-0040-N-216 PIT521102
BAL1150
NB15
TO PIT541101
Open/Close
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
TO
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
10BA04-8010-NI-0020-N-294
Closed
Open/Close
Open/Close
Closed
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
150x65
Closed
10BA04-8011-NI-0150-N-209 65X50
* *
150x65
65X50
* *
Closed
Closed
TO
Open/Close
FIT521104.01
BAL0405
Closed
Closed
NB15
TO
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
Open/Close
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
REMOVABLE PERMANENT
TO
FIT521104.02
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
Open/Close
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
TO
PDIT521110.01
Closed
BAL1151
NB15
TO
Open/Close
10BA04-8011-NI-0040-N-216 PIT521102
BAL1150
NB15
TO PIT541101
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
TO
Open/Close
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
Open/Close
10BA04-8010-NI-0020-N-294
Closed
Closed
10BA04-8010-NI-0020-N-293
10BA04-8010-NI-0020-N-292
10BA04-8010-NI-0020-N-291
10BA04-8010-NI-0020-N-290
Disconnect/connect
10BA04-8010-NI-0020-N-591
150x65
Closed
10BA04-8011-NI-0150-N-209 65X50
* *
150x65
65X50
* *
Closed
Closed
Disconnect flange
TO
FIT521104.01
BAL0405
Closed
Closed
Closed
NB15
TO
10BA04-8011-NI-0100-N-223 FIT521104.01
BAL0404
10BA04-8011-NI-0080-N-220 NB15
TO
BAL0403 PIT521104.01
NB15
TO
10BA04-8011-NI-0040-N-225 FIT521104.02
BAL0402
NB15
REMOVABLE PERMANENT
TO
FIT521104.02
BAL0401
NB15
TO
10BA04-8011-NI-0100-N-213 BAL0400 PIT521104.02
NB15
Open/Close
TO
PIT511103.01
50x40 BAL1140
NB15
TO
* * PIT511103.02
BAL1139
NB15
TO
PDIT521110.02
50x40 BAL1154
NB15
* TO
* PDIT521110.02
BAL1153
NB15
TO
10BA04-8011-NI-0050-N-211 PDIT521110.01
BAL1152
NB15
TO
PDIT521110.01
BAL1151
NB15
TO
10BA04-8011-NI-0040-N-216 PIT521102
Open/Close
BAL1150
Open/Close
NB15
TO PIT541101
BAL1149
NB15
TO
PDIT511101.02
BAL1148
NB15
TO
PDIT511101.02
BAL1147
NB15
TO
PDIT511101.01
BAL1146
NB15
TO
PDIT511101.01
BAL1145
NB15
TO
PIT511101.01
10BA04-8010-NI-0020-N-295 BAL1144
NB15 TO
PIT511101.02
10BA04-8010-NI-0020-N-294
Closed
Closed
10BA04-8010-NI-0020-N-293
10BA04-8010-NI-0020-N-292
10BA04-8010-NI-0020-N-291
Disconnect/connect
10BA04-8010-NI-0020-N-290
10BA04-8010-NI-0020-N-591
COMMESSA / JOB
____________________
PW Drawing number CDQ – 11 COKE OVEN GAS L&T

L&T Drawings number
(to be listed here)
GENERAL P&I .
1680 80 U 02 019 – CDQ 11
1680 50 K 02 006 – CDQ 11

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 YES NO
the line

2 According to P&ID 168080U02019, YES NO
168050K02006

Acting from greater diameters to small diameters
3 YES NO
disconnected

4 YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 2
ESA-80-019-CDQ 11 COG END OF ERECTION.doc

COMMESSA / JOB
____________________

MOP = 1.153 bar
be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 2
ESA-80-019-CDQ 11 COG END OF ERECTION.doc

COMMESSA / JOB
____________________
PW Drawing number CDQ11 – Coke oven gas L&T

L&T Drawings number
GENERAL P&I .
1680 80 U 02 019 – CDQ 11

MAIN LINE TAG

2.5BA02-8011-GT-0250-N-305
10BA04-8011-WS-0080-N-304

1 YES NO
the line

2.5BA02-8011-GT-0250-N-305
2 YES NO
10BA04-8011-WS-0080-N-304

3 YES NO
disconnected
Disconnect flange after valve GV1068NB250 and

3a YES NO
connect in this poin compressed air
Open valve GV0322NB100 and flushing with

3b YES NO
comressed air line, then close valve
3c Open valve BAL0421NB15 and flushing with YES NO

compressed air on sampling line, then close

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 3
ESA-80-019- CDQ 11 COG Loop1 END OF ERECTION.doc

COMMESSA / JOB
____________________

valve.
Open valve GV0311NB250 and flushing

3d YES NO
hydraulic seal to pit, then close valve.
3e Blanked out the hydraulic seal YES NO
3f Open valve GV0311NB250 YES NO

3g 10BA04-8011-WS-0080-N-304 to pit, then close
valve
Open valve GV0323NB100 and flushing line,

3h YES NO
then close valve.
Open valve BAL0422NB15 and flushing to

3i YES NO
sampling line, then close valve.
3j Close valve GV0311NB250 YES NO
3k Disconnect flange before valve GV1069NB250 YES NO

3l YES NO
2.5BA02-8011-GT-0250-N-305, then close valve
3m Connect flange before valve GV1069NB250 YES NO

MOP = 1.153 bar
4 YES NO
Pressure 1.073 – 1.153 bar.

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

be noted.


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 019 – CDQ 11
1680 50 K 02 006 – CDQ 11

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 YES NO
the line

2.5BA02-8000-GT-0250-N-352
2.5BA02-8000-GT-0250-N-346
2 YES NO
2.5BA02-8000-GT-0025-N-343
According to P&ID 168080U02019,
168050K02006

3 YES NO
disconnected
Disconnect flange after valve GV1068NB250 and

3a YES NO
connect on this point compressed air

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 3
ESA-80-019- CDQ 11 COG Loop 2 END OF ERECTION.doc

COMMESSA / JOB
____________________

3b Open valve GV0311NB250 YES NO
Disconnect flange end of line 2.5BA02-8000-GT-

3c 0250-N-346 in the place of connection to the YES NO
burner
Disconnect flange end of line 2.5BA02-8000-GT-

3d 0025-N-343 in the place of connection to the YES NO
burner
3e Open valve GV1069NB250 YES NO
Open butterfly valve SOV510090.01NB250

Open butterfly valve FV510091.01NB250
3f and flushing line 2.5BA02-8000-GT-0250-N-352, YES NO
2.5BA02-8000-GT-0250-N-346
After flusing close butterfly valves.
Open BAL0291NB25 and SOV510092NB25,

3g flushing line 2.5BA02-8000-GT-0025-N-343, then YES NO
close valves
3h Close valve GV1069NB250 YES NO
3i Close valve GV0311NB250 YES NO
Connect flange end of line 2.5BA02-8000-GT-

3j 0250-N-346 in the place of connection to the YES NO
burner
Connect flange end of line 2.5BA02-8000-GT-

3k 0025-N-343 in the place of connection to the YES NO
burner
4 Pneumatic test of line BEFORE PAINTING YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 2 / 3

COMMESSA / JOB
____________________

MOP = 1.153 bar
be noted.
Control circuit leakage. In case of fail of test (4a)

and test again as per point (4a)


________________ ________________ ________________
GENERAL NOTES
PAG 3 / 3

COMMESSA / JOB
____________________

L&T Drawings number
GENERAL P&I .
1680 80 U 02 019 – CDQ 11

MAIN LINE TAG

2.5BA02-8011-GT-0025-N-304

1 YES NO
the line

2 2.5BA02-8011-GT-0025-N-304 YES NO

3 YES NO
disconnected
Open valves BAL1001NB25, BAL0388NB25

3a flushing line 2.5BA02-8011-GT-0025-N-304 YES NO
In to emergency flare, then close valves.

4 MOP = 1.153 bar YES NO

________________ ________________ ________________
GENERAL NOTES
PAG 1 / 2

COMMESSA / JOB
____________________

be noted.
Control circuit leakage. In case of fail of test (4a)

and test again as per point (4a)
4b Disconnect compressed air, connect flange after YES NO

valve GV1068NB250


________________ ________________ ________________
GENERAL NOTES
PAG 2 / 2

10BA04-8000-AP-0025-N-348
2.5BA02-8000-GT-0025-N-343
600x600
10BA04-8011-AP-0600-N-254 FE511150
Open/close
Open/close
Disconnect/connect
ZT
510091.01
Open/close
Disconnect/connect
I.A.
FV510091.01
NB250
ZT
510099
I.A.
FV510099
NB1000
Open/close Open/close
Disconnect/connect
Disconnect flange and connect Open/close

compressed air line
BAL0420
BAL0419
NB15
NB15
BAL0417
NB40
BAL0418
NB40
Open/close Open/close
10BA04-8011-WS-0080-N-304
compressed air line
Open/close
Disconnect flange and connect
BAL0419
NB15
BAL0420
NB15
BAL0418 BAL0417
NB40 NB40
10BA04-8011-WS-0080-N-304
Open/close
closed
Disconnect flange and connect

compressed air line
BAL0420
BAL0419
NB15
NB15
BAL0417
NB40
Open/close
BAL0418
NB40
closed
10BA04-8011-WS-0080-N-304
50x20 65x50
10BA04-8011-WF-0065-N-177
TO LIT 511101
ELECTRONICS
TO LIT 511102
ELECTRONICS
10BA04-8011-NI-0080-N-196 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
10BA04-8010-NI-0100-N-035
10BA04-8010-NI-0080-N-033
BLIND
10BA04-8010-NI-0050-N-038
I.A.
SV
511050.01
ZSL ZSH
511050.01 511050.01
Pressure Gauge
SOV511050.01
NB600
80x40 M
600x600
600x15 600x25 600x15 600x15
10BA04-8010-AP-0600-N-087 FE511050
MOV511060
168050K02005
10BA04-8010-NI-0040-N-053
10BA04-8010-AP-0600-N-086
40x25
BV0004 CV0003
NB150 NB150
BV0005 CV0004
NB150 NB150
10BA04-5110-PG-0350-R-159
BV0006 CV0005
NB150 NB150
BV0007 CV0006
NB150 NB150
BV0008 CV0007
NB150 NB150
BV0009 CV0008
NB150 NB150
Pressure Gauge
BV0010 CV0009
NB150 NB150
BV0011 CV0010
NB150 NB150
BV0012 CV0011
NB150 NB150
BLIND
BV0013 CV0012
BLIND
Pressure Gauge
NB150 NB150
BV0014 CV0013
NB150 NB150
BV0015 CV0014
NB150 NB150
BV0016 CV0015
NB150 NB150
FROM AE521003.01
FROM AE521003.02
FROM AE521003.03
BV0017 CV0016
NB150 NB150
10BA04-5210-PG-0600-R-160
Pressure Gauge
CV0018
NB15 40x15
10BA04-5210-NI-015-N-357 SOV541003 10BA04-8010-NI-0040-N-036
DN25x15
10BA04-5210-NI-0025-N-358
Pressure Gauge 2.5BA02-8010-GT-0025-N-131
90DUCT-5210-PG-0000-H-008
15x15
BLIND
CLOSED
MOV valve
DN25x15
BLIND
Pressure Gauge
BLIND
CLOSED
MOV valve
Pressure Gauge
FE521004.01
FE521004.02
BLIND
Pressure Gauge
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

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 Reviewed By Approved By.

TECC/ CTF/ QAC/ HTP /001 0 21/02/2017 Vinod.S
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.

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

THERMAX LIMITED.
PUNE
LOOP REGISTOR - CDQ-11

WORKING TEST P&ID
SR.
LOOP NO DRAWING NO REV. DRAWING DESCRIPTION SUB DESCRIPTION AREA PRESSURE PRESSURE COLOUR REMARKS
NO.
(Kg/Cm2) (Kg/Cm2) CODE
P21-2WH-084696 0 DETAIL OF STEAM COLLECTING HEADER STEAM COLLECTING HEADER
P4K-1WH-132759 0 ASSLY. & DETAILS OF RH. SIDE WATER WALL PANEL RH. SIDE WATER WALL PANEL
P4M-1WH-132768 0 ASSLY. & DETAILS OF LH. SIDE WATER WALL PANEL LH. SIDE WATER WALL PANEL
P4N-1WH-132850 0 ASSLY. & DETAILS OF REAR 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 0 ISOMETRIC FOR RISERS R1/1 & R1/6 RISERS R1/1 & R1/6
P71-1WH-132926 0 ISOMETRIC FOR RISERS R4/1,R4/2 & R4/3 RISERS R4/1,R4/2 & R4/3
P71-1WH-132929 0 ISOMETRIC FOR RISERS R6/1,2,3 & R7/1,2,3 RISERS R6/1,2,3 & R7/1,2,3
P73-1WH-132930 0 ISOMETRIC FOR DOWNCOMER D9, D10 & D12 DOWNCOMER D9, D10 & D12
P73-1WH-132931 0 ISOMETRIC FOR DOWNCOMER D1, D2, D7 & D11 DOWNCOMER D1, D2, D7 & D11
P73-1WH-132932 0 ISOMETRIC FOR DOWNCOMER D3,D4,D5,D6 & D8 DOWNCOMER D3,D4,D5,D6 & D8
ASSLY.OF SUPER HEATER-IA,IB & II COILS WITH SUPPORT SUPER HEATER-IA,IB & II COILS WITH SUPPORT TUBE
PA1-1WH-132015 0
TUBE DETAILS DETAILS
INLET & OUTLET HEADER DETAILS OF SUPER HEATER 1A,1B INLET & OUTLET HEADER DETAILS OF SUPER HEATER
PA3-1WH-132026 0 PRESSURE PART
&2 1A,1B & 2
PB1-1WH-133271 0 ASSEMBLY AND DETAILS OF ATTEMPERATOR 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 0 INLET & OUTLET HEADERSS OF EVPORATOR-1 INLET & OUTLET HEADERSS OF EVPORATOR-1
PD4-1WH-131848 0 INLET & OUTLET HEADERSS OF EVPORATOR-2 INLET & OUTLET HEADERSS OF EVPORATOR-2
PE1-1WH-132890 0 DETAIL OF SUPPORT TUBE (TYPE-1) SUPPORT TUBE (TYPE-1)
PE1-1WH-132891 0 DETAIL OF SUPPORT TUBE (TYPE-II) SUPPORT TUBE (TYPE-II)
1 CDQ-11/BLR/HT/001 82 123
PE1-1WH-132892 0 DETAIL OF SUPPORT TUBE (TYPE-III) SUPPORT TUBE (TYPE-III)
PE1-1WH-132893 0 ASSLY. & DETAIL OF SUPPORTING TUBES TOP HEADER 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
DETAIL OF INLET & OUTLET HEADER FOR ECONOMISER-I &
PM3-1WH-131801 0 INLET & OUTLET HEADER FOR ECONOMISER-I & II
II
Z11-1WH-133597 3 INTEGRAL PIPING-I STEAM DRUM ACESSORIESS
Z11-1WH-133598 3 INTEGRAL PIPING-II ECO TO SD, LP STEAM, IBD PPG,HP DOSING BLIND ON IBD PPG
SUPERHEATED STEAM PIPING AND START UP VENT
Z11-1WH-133599 3 INTEGRAL PIPING-III INTEGRAL PIPING
PIPING
Z11-1WH-133600 3 INTEGRAL PIPING-IV SATURATED STEAM PIPING
Z11-1WH-133601 3 INTEGRAL PIPING-V ATTEMPORATOR I/L AND O/L PIPING
Z1G-1WH-134059 3 NON INTEGRAL PIPING- VI SPRAY WATER PIPING BLIND AT TP-03
BLIND AT TP-07 (SAMPLING LINE)
BLIND AT CBD TANK FLANGE
Z1G-1WH-134060 3 NON INTEGRAL PIPING- VII CBD SAMPLING PIPING
(FE 531103 CAN BE INSTALLED AFTER
HYDROTEST)
Z1G-2WH-085950 3 NON INTEGRAL PIPING-X IBD PIPING BLIND AT IBD TANK FLANGE
Z1H-1WH-134045 3 NON INTEGRAL PIPING-I MAIN STEAM PIPING CLOSE AT A-B LOCATION
Z1H-1WH-134046 3 NON INTEGRAL PIPING-II STEAM DRUM ACESSORIESS
BLIND AT TP-05
Z1H-1WH-134049 3 NON INTEGRAL PIPING-V MAIN STEAM SAMPLING PIPING NON INTEGRAL PIPING
BLIND AT TP-06
CLOSE SECOND ISOLATION VALVES AT D1/D2
Z1I-1WH-134278 3 NON INTEGRAL DRAIN PIPING-I IBD TANK DRAIN
PRESSURE DROP
CLOSE SECOND ISOLATION VALVES IN DC
Z1I-1WH-134279 3 NON INTEGRAL DRAIN PIPING-II DRAIN FOR DC -D1 & D2
DRAINS
BLIND AT TP-04
Z1I-2WH-086183 3 HP DOSING PIPING HP DOSING PIPING (CV5012- EITHER REVERSE THE DIRECTION OR
DROP FOR HYDROTEST.)
Z1I-2WH-086296 3 NON INTEGRAL VENT PIPING FOR ECONOMISER
COMMON DRAIN PIPING-
2 CDQ-11/BLR/HT/002 Z1I-1WH-134278 3 NON INTEGRAL DRAIN PIPING-I COMMON DRAIN PIPING-STEAM 8.2 12.3 BLIND AT IBD FLANGE
STEAM
COMMON DRAIN PIPING-
3 CDQ-11/BLR/HT/003 Z1I-1WH-134279 3 NON INTEGRAL DRAIN PIPING-II COMMON DRAIN PIPING-WATER 8.2 12.3 BLIND AT IBD FLANGE
WATER
4 CDQ-11/BLR/HT/004 Z1H-1WH-134048 3 NON INTEGRAL PIPING-IV LP STEAM NON INTEGRAL LP STEAM NON INTEGRAL 12 18 BLIND AT TP-02
Z1G-1WH-134061 3 NON INTEGRAL PIPING- VIII CBD TANK MOUNTINGS CBD/IBD MOUNTING,
5 CDQ-11/BLR/HT/005 3 4.5
Z1G-1WH-134080 3 NON INTEGRAL PIPING-IX CBD,IBD INTERCONNECTING PIPING DRAIN AND LINK PIPING BLIND AT IBD FLANGE
BLING ALL EMPTY FLANGE LOCATION OR TP
Z1H-1WH-134047 3 NON INTEGRAL PIPING-III DEARATOR MOUNTINGS
FLANGES
DEARATOR AND RELATED BLIND AT DOWN STREAM OF GV5032
6 CDQ-11/BLR/HT/006 5 7.5
PIPING (DEARATOR DRAIN)
Z1H-1WH-134048 3 NON INTEGRAL PIPING-IV DEARATOR DRAIN PIPING
BLIND AT DOWNSTREAM OF GV5038 (BOILER
FEED PUMP SUCTION)
Z11-2WH-087719 0 INTEGRAL PIPING-VI SUB ECO HDR I/L PPG BLIND ON PSV 531109 FLANGE
Z1G-1WH-134061 3 NON INTEGRAL PIPING- VIII SUB ECO I/L & O/L HDR MOUNTINGS
BLIND AT TPS-2
SUB ECONOMISER COIL
7 CDQ-11/BLR/HT/007 Z1G-1WH-134062 3 NON INTEGRAL PIPING- XI SUB ECO I/L PIPING 7 10.5 BLING ON PSV 531108 FLANGE
AND PIPING
IF REQ. BLIND ON PE FLANGES ALSO
Z1G-1WH-134063 3 NON INTEGRAL PIPING-XII SUB ECO O/L PIPING BLIND AT TPS-1
PL1-1WH-132158 2 SUB ECONOMISER COIL -NON INTEGRAL SUB ECONOMISER COIL
MAIN STEAM PIPING-START UP VENT AFTER CONTROL NOT NECESSORRY TO HYDRO-OPEN TO
Z1H-1WH-134045 3 NON INTEGRAL PIPING-I
VALVE ATMOSPHERE - BLIND ON SILENCER FLANGE
SUPERHEATED STEAM PIPING AND START UP VENT FE 531102.03 IN MSL LINE - TO BE INSTALLED
Z11-1WH-133599 3 INTEGRAL PIPING-III
PIPING AFTER HYDRO AND STEAM BLOWING
HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO
Z13-1WH-134276 3 NON INTEGRAL VENT PIPING-1 SD PSV VENT PIPING
ATMOSPHERE
HYDRO NOT MANDETORY - HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO
8 CDQ-11/BLR/HT/008 Z13-1WH-134277 3 NON INTEGRAL VENT PIPING-II MAIN STEAM PSV VENT _____
OPEN TO ATMOSPHERE ATMOSPHERE
HYDRO SHOWS AT 12.3 KG.CM2 -LINE OPEN TO
Z13-1WH-134293 3 NON INTEGRAL VENT PIPING-III MAIN STEAM ERV VENT PIPING
ATMOSPHERE
HYDRO SHOWS AT 1.965 KG.CM2 -LINE OPEN
Z13-1WH-134304 3 NON INTEGRAL VENT PIPING-IV CBD TANK PSV VENT PIPING
TO ATMOSPHERE
Z13-2WH-086180 3 OPEN DRAIN PIPING OPEN DRAIN PIPING OPEN DRAIN PIPING
FE 531103 IN CBD LINE - TO BE INSTALLED
Z1G-1WH-134060 3 NON INTEGRAL PIPING- VII CBD SAMPLING PIPING
AFTER HYDRO TEST
Z1H-1WH-134045 3 NON INTEGRAL PIPING-I MAIN STEAM PIPING MSL FE MOUNTINGS- NON INTEGRAL
SJ531104
SJ531103
SATURATED STEAM & WATER DRAIN HEADER
SJ531102
SUPERHEATER DRAIN HEADER
OTHERS TL
1680 80 U 02 018
FE TO BE INSTALLED
TL AFTER STEAM BLOWING
SJ531101
OTHERS
TYP. FOR ALL INCHING TYPE OF
TP-05 MOTORISED VALVES
TL
OTHERS
TP-06
BLR531101
1680 80 U 02 013 OTHERS
TYP. FOR ALL ON/OFF TYPE
TL FLUE GAS IN MOTORISED VALVES
CUSTOMER TO CONFIGURE DI & DO'S IN THEIR DCS.
BST531102
OTHERS TL
TL
SECONDARY SUPER HEATER
OTHERS TL OTHERS
VALVE IS NOT IN THERMAX SCOPE-UP TO VALVE TP-07
DSH531101
SHOULD BE COMPLETED BEFORE HYDROTEST
1680 53 G 02 102
1680 80 U 02 004
SJ531105
OTHERS TL OTHERS PRIMARY SUPER HEATER
1680 53 G 02 103 TP-04 TL

OTHERS FE TO BE ERECTED
NRV TO BE
TL AFTER HYDROTEST
NRV TO BE ERECTED AFTED
ERECTED AFTER HYDROTEST
HYDROTEST TO STEAM DRUM
IBT531104 CBT531103
1680 80 U 02 012 EVAPORATOR-1
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 ECONOMISER LOOP NO - 1
SHOULD BE COMPLETED BEFORE HYDROTEST
LOOP NO - 2
OTHERS TL
1680 53 G 02 102
TL OTHERS
LOOP NO - 3
LOOP NO - 4
LOOP NO - 5
GAS OUT
TATA CONSULTING ENGINEERS LIMITED

MUMBAI TATA STEEL LTD.
OTHERS TL
TP-03

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

OTHERS MOTORISED VALVES
OTHERS TL
TL
TL
OTHERS
TYP. FOR ALL ON/OFF TYPE

MOTORISED VALVES
CUSTOMER TO CONFIGURE DI & DO'S IN THEIR DCS.
TL OTHERS
TL
TL 1680 80 U 02 020
OTHERS
OTHERS
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 DCP531110
CHAMBER
OTHERS FOR Y-PHASE

TL
TL OTHERS
SBE531107
DFP531108
SUB-ECONOMISER
1680 80 U 02 014
FOR B-PHASE
1680 80 U 02 101
1680 53 G 02 103
TL FWP531111
OTHERS OTHERS TL
OTHERS
TL
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
FWP531112
OTHERS OTHERS TL
TL
OTHERS TL TL OTHERS
1680 80 U 02 017
OTHERS TL TATA CONSULTING ENGINEERS LIMITED
TL OTHERS
MUMBAI TATA STEEL LTD.
1680 80 U 02 017

THERMAX ENGINEERING CONSTRUCTION COMPANY LIMITED.
PUNE
JOB SAFETY ANALSIS FOR HYDRO TESTING
PROJECT:- .
JOB No.:-
JSA NO:-
ACTIVITY 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.
Pressurising & Use calibrated pressure gauges/equipments & ensure pressure does not exceed specified value.
Depressurising of Proper no. of Vents & drains to be provided as per requirement.
Damage to equipment from
Pipelines / Vessel with Provide arrangement for release of excess pressure(eg. PSV) in case of accidental pressure increase.
accidental rise in pressure.
water 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.
Opening / box up of
Cricket helmet to be worn while tightening and loosing of bolts whereever required.
flanges
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 Checked by Reviewed by
Note: Contractor Supervisor shall give job specific tool box talk to all workers.
LOOP INDEX
THERMAX ECC LTD.
BOILER NO. : - TEST PACKAGE NO.:-
ATTACHED
SR. NO. INDEX RECORD FORMAT NO. REMARK
Yes 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
LINE MECHANICAL CLEARANCE REPORT

9 (FOR HYDROTEST)
TECC/QAC/LOOP/HT/0007
10 LINE HISTORY SHEET TECC/QAC/LOOP/HT/0008
PRE TEST CRITICAL COMPONENTS PLACEMENT / REMOVAL AND

10 REINSTATEMENT
PIPING TEST PACKAGE CLEARANCE REPORT FOR PRESSURE

11 TESTING
12 PIPING PRESSURE TEST RECORD TECC/QAC/LOOP/HT/0011
JOBS CARRIED OUT ON MECHANICALLY CLEARED SYSTEM /

13 SUBSYSTEM (LOOPS)
ERECTION VENDOR THERMAX ECC CONSULTANT CUSTOMER
NAME
SIGNATURE
DATE
Page 1 of 1
LINE LIST
THERMAX ECC LTD.
BOILER NO. : TEST PACKAGE NO.:
DESIGN TEST
SR.
ISO DRG.NO. REV. P&I D No. REV. LINE DESCRIPTION PRESSURE PRESSURE TEST MEDIUM
NO.
(Kg/cm2) (Kg/cm2)
Remarks:
NAME
SIGNATURE
DATE
FORMAT NO. :- TECC/QAC/LOOP/HT/0001
Page 1 of 1
VALVE LIST
THERMAX ECC LTD.
BOILER NO:- TEST LOOP NO.:
Direction as
VALVE SERIAL
SR. NO. DRAWING NO. REV. SIZE & VALVE SPECIFICATION TYPE OF VALVE ISO TAG NO. per ISO Remarks
NO. / BAAN NO.
(YES / NO)
NAME
SIGNATURE
DATE
Page 1 of 1
FLANGE VARIFICATION REPORT
THERMAX ECC LTD.
BOILER NO. : TEST LOOP NO.:
ALIGNMENT READING
FLANGE FLANGE SIZE AND VISUAL INSPECTION GASKET TYPE & RATING FASTNERS MATERIAL SPEC. TORQUE PRESSURE
(REF. FIG 1 FOR TOLERENCE) MOLYCOTE
SR. NO. DRAWING NO. JOINT NO. RATING OF FLANGE FACE REMARKS
0 90 180 270 REQUIRED REQUIRED 1000 APPLIED REQUIRED
(A) (B) (ACCEPT/DAMAGED) VARIFIED VARIFIED OBTAINED
DEG DEG DEG DEG (C) (D) (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 CUSTOMER
NAME
SIGNATURE
DATE
Page 1 of 1
SUPPORT VARIFICATION REPORT
THERMAX ECC LTD.
Slide
Position* Gap Spring
Support are
Guid Washer Welding of
SR. SUPPORT DRAWING SUPPORT NO. Free & Not
ISO DRAWING NO. SUPPORT TYPE Packing Direction Provided for Support Remarks
NO. NO. (NOTE-1) Location & Resting & Tack Welded
Provided & As per Drg. Actual Checked* Clamp Type Complete*
Dimention Centering to Base
Welded Support*
Plate*
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.)
NAME
SIGNATURE
DATE
Page 1 of 1
SPRING SUPPORT VARIFICATION REPORT
THERMAX ECC LTD.
COLD SETTING VALUE PROVISION OF
SR. SPRING NO. SPRING DATA SHEET SPRING CAGE SPRING PIN LOCK POSITION AFTER WELDING OF
ISO DRAWING NO. SPRING TYPE PRESET GAP IN Remarks
NO. (TAG NO.) NO. & REV. /CLH RATING DEGGAGING SETTING SUPPORT
DESIGN ACTUAL TURN BUCKLE
NAME
SIGNATURE
DATE
Page 1 of 1
FINAL VISUAL INSPECTION PUNCH LIST
THERMAX ECC LTD.
DATE :
SL. CAT. REMEDIAL ACCEPTANCE DATE AND INITIAL

DRAWING NO. REV. PUNCH ITEM DESCRIPTION TAG No.
NO. A/B
ER. VEND. TECC CONSU. CUST.
Punch List Issued.

NAME
SIGNATURE
DATE
Completed and released for Pressure Testing after Attending 'A' category Point.
NAME
SIGNATURE
DATE
Completed Category 'B' Points.
NAME
SIGNATURE
DATE
Category:
A - Required for Pressure Test. B - Required for Commissioning.

Page 1 of 1
LINE MECHANICAL CLEARANCE REPORT
(FOR HYDROTEST)
THERMAX ECC LTD.
DATE :
Isometric Nos. with Sht & Rev. P&I D No. & Rev.
Sl. No. Description Acceptance

L&T TCE TECC TSL
1.0. PIPING Yes No
1.1 Line verification w.r.t. P&I D, Isometrics
1.2 Check Slope as per grawings
1.3 Test Limits as per marked-up P&I D
1.4 Alignment and clearance from adjacent piping
2.0. SUPPORTS
2.1 All Supports as per Support Standard/Drawing
2.2 Location of Supports as per Iso/GA
2.3 Support Inspection Report attached
2.4 Additional supports provided (if any)
3.0. FLANGES
3.1 All Flanges Properly Aligned
3.2 Correct Type & Rating
3.3 Correct Studs/Bolts, Nuts & Washers
3.4 Gaskets of Correct Type & Rating
3.5 Blind flange rating
3.6 Bolt Tightening
4.0. VALVES
4.1 Check for rating, type, tag no .
Direction of NRV, Control Valves as per GA & P&ID.

4.2
Isolation of Special Items
4.3
Valve stem orientation and access
4.4
Valves deleted for testing (if any)
4.5
Accessibility for Operation.
4.6
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
Remarks :
ERECTION VENDOR THERMAX ECC CONSULTANT CUSTOMER INSPECTION AUTHORITY

NAME
SIGNATURE
DATE
Page 1 of 1
LINE HISTORY SHEET
THERMAX ECC LTD.
LOOP NO.:- DATE
DRG. NO.:- RT %
PT %
JOINT ID SIZE TYPE OF FIT UP CUM RT REPORT NO. DECISION DPT REP. PWHT REP.
SPOOL NO. MATERIAL THK. WPS NO. WELDER NO. REMARKS
NO. (Inch) JOINT W/V REP No. ORIGINAL R1 ACC / REP NO. NO.
Pipe Support Welding (Whereever applicable) No. of Welded Supports in this ISO/Line: 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 CUSTOMER INSPECCTION AUTHORITY

NAME
SIGNATURE
DATE
Page 1 of 1
DATE
NAME
ACTIVITIES
ACTIVITIES
SIGNATURE
HYDROTEST
HYDROTEST
ORDINATOR
ORDINATOR
BOILER NO.:-
ENGINEER / CO-
ENGINEER / CO-
REMOVE TS/ BLINDS /
TEST SPADES /
INSTALL NEW GASKET/
BLINDS INSTALLED
COMPLETE BOLTING
INSTRUMENTS
REINSTATE
REMOVED OR
THERMAX ECC LTD.

INSTRUMENTS
BLOCKED
REINSTAT VALVE CHECK VALVE

INSTRUMENTS / RE INTERNAL REMOVED
ERECTION VENDOR
INSTALL VALVES /JACKED
RE INSTALL SPECIAL SPECIAL PIPING

PIPING ITEMS ITEMS REMOVED
RE INSTATE CONTROL CONTROL VALVES

VALVE REMOVED
REINSTATE PSV/TSV PSV/TSV REMOVED
REINSTATE EXPANSION EXPANSION JOINTS
THERMAX ECC
JOINTS REMOVED
SPRING SUPPORT UN SPRING SUPPORT
Page 1 of 1
GAGGED GAGGED
INSTATEMENT
TEST PACKAGE NO.:-
POST TEST REINSTATEMENT
ORIFICE PLATE
INSTALL ORIFICE PLATE
REMOVED
TEMPORARY SUPPORTS TEMPERORY

REMOVED SUPPORT INSTALLED
PRE TEST CRITICAL COMPONENT PLACEMENT / REMOVAL
PRE TEST CRITICAL COMPONENT PLACEMENT / REMOVAL AND RE
TEMPERORY SPOOLS TEMPORARY SPOOL

CONSULTANT
REMOVD INSTALLED
HOOK UP INSTRUMENT
TUBING
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
Sr. Check Points Yes/No Remarks
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.
Whether suitable type of blind / dummy / standard cap used suitable to pressure being
3
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?
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?
Name :
Signature :
Date :
Page 1 of 1
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
0
2.4 DE MINARALISED WATER TEMPERATURE C
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)
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
LOCATION REMARKS
LEAKAGE YES / NO
3
PRESSURE DROP YES / NO
4 RESULT ACCEPTED / NOT ACCEPTED
ERECTION VENDOR THERMAX ECC CONSULTANT CUSTOMER INSPECTION AUTHORITY
SIGN
NAME
DATE
Page 1 of 1
JOBS CARRIED OUT ON MECHANICALLY CLEARED
SYSTEM / SUB SYSTEM (LOOP)
THERMAX ECC LTD.
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 :
Description of jobs and reason for carrying out this job after
5.0 :
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

Name :
Signature :
Date :
Page 1 of 1
VALVE POSITION WHILE HYDROTEST
SR P&ID TAG LOCATION

PLANT POSITION
NO NO. NO
First Isolation valve at upstream of MOV 531102.01-M on

1 CDQ#11 1680 53 G 02 101 CV5011 CLOSE
Feed Water line
2 CDQ#11 1680 53 G 02 101 GV5090 First Drain Isolation valve at Economiser Inlet Header OPEN
3 CDQ#11 1680 53 G 02 101 GV5091 Second Drain Isolation valve at Economiser Inlet Header CLOSE
4 CDQ#11 1680 53 G 02 101 GV5092 First Isolation valve for vent at Economiser outlet header OPEN
Second Isolation valve for vent at Economiser outlet
5 CDQ#11 1680 53 G 02 101 GV5093 CLOSE
header
FEED WATER TO DESUPERHEATER
First Isolation valve for FIT 531102.26 at upstream of FE
6 CDQ#11 1680 53 G 02 101 GV5062 NA
531124 on Feed Water to desuperheater line
Second Isolation valve for FIT 531102.26 at upstream of
7 CDQ#11 1680 53 G 02 101 GL5016 NA
FE 531124 on Feed Water to desuperheater line
First Isolation valve for FIT 531102.26 at downstream of
8 CDQ#11 1680 53 G 02 101 GV5063 NA
FE 531124 on Feed Water to desuperheater line
Second Isolation valve for FIT 531102.26 at downstream
9 CDQ#11 1680 53 G 02 101 GL5017 NA
of FE 531124 on Feed Water to desuperheater line
First Drain Isolation valve at Upstream of TV 531102.16
10 CDQ#11 1680 53 G 02 101 GV5065 OPEN
on Feed Water to desuperheater line
Second Drain Isolation valve at Upstream of TV
11 CDQ#11 1680 53 G 02 101 GV5066 CLOSE
531102.16 on Feed Water to desuperheater line
First Isolation valve at downstream of TV 531102.16 on
12 CDQ#11 1680 53 G 02 101 GV5067 OPEN
Feed Water to desuperheater line
Isolation valve for bypass of TV 531102.16 on Feed
13 CDQ#11 1680 53 G 02 101 GL5025 OPEN
Water to desuperheater line
Isolation valve upstream of desuperheater on feed water
14 CDQ#11 1680 53 G 02 101 CV5010 OPEN
to desuperheater line
First Isolation valve for drain on feed water to
14 CDQ#11 1680 53 G 02 101 GV5068 OPEN
desuperheater line
Second Isolation valve for drain on feed water to
15 CDQ#11 1680 53 G 02 101 GV5069 CLOSE
desuperheater line
PLANT POSITION
NO NO. NO
STEAM DRUM
Isolation valve for PG 531102.18 on BST531102 (Steam
16 CDQ#11 1680 53 G 02 101 GL5063 CLOSE
Drum)
First Isolation valve for PG 531102.08 on BST531102
17 CDQ#11 1680 53 G 02 101 GV5122 OPEN
(Steam Drum)
Second Isolation valve for PG 531102.08 on BST531102
18 CDQ#11 1680 53 G 02 101 GL5039 CLOSE
(Steam Drum)
First Isolation valve for PIT 531102.07 on BST531102
19 CDQ#11 1680 53 G 02 101 GV5124 OPEN
(Steam Drum)
Second Isolation valve for PIT 531102.07 on BST531102
20 CDQ#11 1680 53 G 02 101 GL5038 CLOSE
(Steam Drum)
21 CDQ#11 1680 53 G 02 101 GV5144 First Isolation valve for vent on Puppy header OPEN
22 CDQ#11 1680 53 G 02 101 GV5145 Second Isolation valve for vent on Puppy header CLOSE
23 CDQ#11 1680 53 G 02 101 GV5095 First top Isolation valve for LIT 531102.01 OPEN
24 CDQ#11 1680 53 G 02 101 GL5026 Second top Isolation valve for LIT 531102.01 CLOSE
25 CDQ#11 1680 53 G 02 101 GV5097 First bottom Isolation valve for LIT 531102.01 OPEN
26 CDQ#11 1680 53 G 02 101 GL5027 Second bottom Isolation valve for LIT 531102.01 CLOSE
39 CDQ#11 1680 53 G 02 101 GV5099 First top Isolation valve for LG 531102.05 OPEN
40 CDQ#11 1680 53 G 02 101 GL5028 Second top Isolation valve for LG 531102.05 CLOSE
41 CDQ#11 1680 53 G 02 101 GV5101 First bottom Isolation valve for LG 531102.05 OPEN
42 CDQ#11 1680 53 G 02 101 GL5029 Second bottom Isolation valve for LG 531102.05 CLOSE
43 CDQ#11 1680 53 G 02 101 GV5102 First isolation valve for drain of LG 531102.05 OPEN
44 CDQ#11 1680 53 G 02 101 GV5103 Second isolation valve for drain of LG 531102.05 CLOSE
45 CDQ#11 1680 53 G 02 101 GV5094 First isolation valve for vent of LG 531102.05 OPEN
46 CDQ#11 1680 53 G 02 101 GV5096 Second isolation valve for vent of LG 531102.05 CLOSE
47 CDQ#11 1680 53 G 02 101 GV5116 First top Isolation valve for LG 531102.06 OPEN
48 CDQ#11 1680 53 G 02 101 GL5036 Second top Isolation valve for LG 531102.06 CLOSE
49 CDQ#11 1680 53 G 02 101 GV5118 First bottom Isolation valve for LG 531102.06 OPEN
50 CDQ#11 1680 53 G 02 101 GL5037 Second bottom Isolation valve for LG 531102.06 CLOSE
51 CDQ#11 1680 53 G 02 101 GV5120 First isolation valve for drain of LG 531102.06 OPEN
52 CDQ#11 1680 53 G 02 101 GV5121 Second isolation valve for drain of LG 531102.06 CLOSE
53 CDQ#11 1680 53 G 02 101 GV5089 First isolation valve for vent of LG 531102.06 OPEN
54 CDQ#11 1680 53 G 02 101 GV5081 Second isolation valve for vent of LG 531102.06 CLOSE
55 CDQ#11 1680 53 G 02 101 GV5227 First isolation valve on N2 injection line to Steam Drum OPEN
Second isolation valve on N2 injection line to Steam

56 CDQ#11 1680 53 G 02 101 GV5228 CLOSE
Drum
Isolation valve for vent on N2 injection line to Steam
57 CDQ#11 1680 53 G 02 101 GV5229 CLOSE
Drum
First Isolation valve for drain on Blowown line from Steam
58 CDQ#11 1680 53 G 02 101 GV5143 OPEN
drum to CBD Tank
Second Isolation valve for drain on Blowdown line from
59 CDQ#11 1680 53 G 02 101 GL5008 CLOSE
Steam drum to CBD Tank
60 CDQ#11 1680 53 G 02 101 GV5206 First isolation valve on IBD line from Steam Drum OPEN
61 CDQ#11 1680 53 G 02 101 GV5196 First Isolation valve for drain at Evaporator I inlet header OPEN
Second Isolation valve for drain at Evaporator I inlet
62 CDQ#11 1680 53 G 02 101 GV5197 CLOSE
header
63 CDQ#11 1680 53 G 02 101 GV5198 First Isolation valve for drain at Evaporator II inlet header OPEN
Second Isolation valve for drain at Evaporator II inlet
64 CDQ#11 1680 53 G 02 101 GV5199 CLOSE
header
Second Isolation valve for vent on steam line from
65 CDQ#11 1680 53 G 02 101 GV5147 OPEN
steamdrum to primary superheater
First Isolation valve for vent on steam line from
66 CDQ#11 1680 53 G 02 101 GV5146 CLOSE
First Isolation valve for SWAS system on steam line from
67 CDQ#11 1680 53 G 02 101 GV5148 OPEN
Second Isolation valve for SWAS system on steam line
68 CDQ#11 1680 53 G 02 101 GL5010 CLOSE
from steamdrum to primary superheater
69 CDQ#11 1680 53 G 02 101 GV5202 First Isolation Valve for support tube drain OPEN
70 CDQ#11 1680 53 G 02 101 GV5203 Second Isolation Valve for support tube drain CLOSE
71 CDQ#11 1680 53 G 02 101 GV5200 First Isolation Valve at water wall header drain OPEN
72 CDQ#11 1680 53 G 02 101 GV5201 Second Isolation Valve at water wall header drain CLOSE
Isolation valve on LP steam line to Evaporator I inlet
73 CDQ#11 1680 53 G 02 101 GV5225 CLOSE
header
Isolation valve on LP steam line to Evaporator II inlet
74 CDQ#11 1680 53 G 02 101 GV5226 CLOSE
header
PLANT POSITION
NO NO. NO
MAIN STEAM LINE

First Isolation valve for drain at Primary Superheater inlet
75 CDQ#11 1680 53 G 02 101 GV5149 OPEN
header
Second Isolation valve for drain at Primary Superheater
76 CDQ#11 1680 53 G 02 101 GV5150 CLOSE
inlet header
Second Isolation valve for vent at Primary Superheater
77 CDQ#11 1680 53 G 02 101 GV5152 CLOSE
outlet header
First Isolation valve for vent at Primary Superheater
78 CDQ#11 1680 53 G 02 101 GV5151 OPEN
outlet header
Second Isolation valve for vent at Secondary
79 CDQ#11 1680 53 G 02 101 GV5154 CLOSE
Superheater Inlet header
First Isolation valve for vent at Secondary Superheater
80 CDQ#11 1680 53 G 02 101 GV5153 CLOSE
Inlet header
First Isolation valve for drain at Secondary Superheater
81 CDQ#11 1680 53 G 02 101 GV5155 OPEN
outlet header
Second Isolation valve for drain at Secondary
82 CDQ#11 1680 53 G 02 101 GV5156 CLOSE
Superheater outlet header
First Isolation valve for PG 531102.15 upstream of FIT
83 CDQ#11 1680 53 G 02 101 GV5232 NA
531102.04 on Main Steam Line
Second Isolation valve for PG 531102.15 upstream of
84 CDQ#11 1680 53 G 02 101 GL5062 NA
FIT 531102.04 on Main Steam Line
85 CDQ#11 1680 53 G 02 101 GV5157 NA
531115 in Feed Water line
86 CDQ#11 1680 53 G 02 101 GL5046 NA
87 CDQ#11 1680 53 G 02 101 GV5159 NA
88 CDQ#11 1680 53 G 02 101 GL5047 NA
89 CDQ#11 1680 53 G 02 101 GV5161 NA
90 CDQ#11 1680 53 G 02 101 GL5048 NA
91 CDQ#11 1680 53 G 02 101 GV5167 NA
FE 531126 in Main Steam line
92 CDQ#11 1680 53 G 02 101 GL5051 NA
of FE 531126 in Main Steam line
93 CDQ#11 1680 53 G 02 101 GV5165 NA
94 CDQ#11 1680 53 G 02 101 GL5050 NA
95 CDQ#11 1680 53 G 02 101 GV5163 NA
96 CDQ#11 1680 53 G 02 101 GL5049 NA
First Isolation valve for PIT 531102.09 on Main Steam
97 CDQ#11 1680 53 G 02 101 GV5169 OPEN
Line
Second Isolation valve for PIT 531102.09 on Main Steam
98 CDQ#11 1680 53 G 02 101 GL5052 CLOSE
Line
99 CDQ#11 1680 53 G 02 101 GV5171 OPEN
Line
100 CDQ#11 1680 53 G 02 101 GL5053 CLOSE
Line
101 CDQ#11 1680 53 G 02 101 GV5173 OPEN
Line
102 CDQ#11 1680 53 G 02 101 GL5054 CLOSE
Line
103 CDQ#11 1680 53 G 02 101 GV5175 OPEN
Line
PLANT POSITION
NO NO. NO

104 CDQ#11 1680 53 G 02 101 GL5055 CLOSE
Line
Isolation Valve upstream of PV 531102.18 - Startup vent
105 CDQ#11 1680 53 G 02 101 GV5177 CLOSE
valve
First isolation valve for drain upstream of PV
106 CDQ#11 1680 53 G 02 101 GV5178 OPEN
531102.18 - startup vent valve
Second isolation valve for drain upstream of PV
107 CDQ#11 1680 53 G 02 101 GV5236 CLOSE
531102.18 - startup vent valve
Isolation Valve Downstream of PV 531102.18 - Startup
108 CDQ#11 1680 53 G 02 101 GV5179 CLOSE
vent valve
Isolation Valve upstream of PV 531102.17 - Startup vent
109 CDQ#11 1680 53 G 02 101 GV5180 OPEN
valve
First Isolation valve for drain upstream of PV
110 CDQ#11 1680 53 G 02 101 GV5181 OPEN
531102.17 - bypass startup vent valve
Second isolation valve for drain upstream of PV
111 CDQ#11 1680 53 G 02 101 GV5237 CLOSE
531102.17 - bypass startup vent valve
Isolation Valve Downstream of PV 531102.17 - bypass
112 CDQ#11 1680 53 G 02 101 GV5182 CLOSE
Startup vent valve
First Isolation valve for drain to SWAS on main steam
113 CDQ#11 1680 53 G 02 101 GV5183 OPEN
line
Second Isolation valve for drain to SWAS on main steam
114 CDQ#11 1680 53 G 02 101 GL5011 CLOSE
line
Isolation Valve upstream of PV 531102.20 on Main
115 CDQ#11 1680 53 G 02 101 GV5184 OPEN
Steam Line
First Isolation valve for drain upstream of PV 531102.20
116 CDQ#11 1680 53 G 02 101 GV5185 OPEN
on main steam line
Second Isolation valve for drain upstream of PV
117 CDQ#11 1680 53 G 02 101 GV5186 CLOSE
531102.20 on main steam line
Isolation Valve Downstream of PV 531102.20 on Main
118 CDQ#11 1680 53 G 02 101 GV5187 OPEN
Steam Line
Isolation Valve Upstream of PV 531102.19 on Main
119 CDQ#11 1680 53 G 02 101 GV5188 OPEN
Steam Line
First Isolation valve for drain upstream of PV 531102.19
120 CDQ#11 1680 53 G 02 101 GV5189 OPEN
on main steam line
Second Isolation valve for drain upstream of PV
121 CDQ#11 1680 53 G 02 101 GV5190 CLOSE
531102.19 on main steam line
Isolation Valve Downstream of PV 531102.19 on Main
122 CDQ#11 1680 53 G 02 101 GV5191 OPEN
Steam Line
First Isolation valve for PIT 531102.19 upstream of PV
123 CDQ#11 1680 53 G 02 101 GV5192 CLOSE
531102.20 on Main Steam Line
Second Isolation valve for PIT 531102.19 upstream of
124 CDQ#11 1680 53 G 02 101 GL5056 CLOSE
PV 531102.20 on Main Steam Line
Isolation valve upstream of MOV 531102.23-M on main
125 CDQ#11 1680 53 G 02 101 CV5014 AUTO
steam line
First Isolation valve for drain upstream of MOV
126 CDQ#11 1680 53 G 02 101 GV5194 OPEN
531102.023-M on Main Steam Line
Second Isolation valve for drain upstream of MOV
127 CDQ#11 1680 53 G 02 101 GV5195 CLOSE
531102.023-M on Main Steam Line
CHEMICAL INJECTION TO STEAM DRUM
128 CDQ#11 1680 53 G 02 101 CV5012 First isolation valve on HP dosing line to Steam Drum OPEN
129 CDQ#11 1680 53 G 02 101 GV5205 Second isolation valve on HP dosing line to Steam Drum CLOSE
Hydrotest Pressurisation & De-pressurisation Curve
130
120 Hydro-test Pressure

110
123 kg/cm2 (g)
100
90
Pressure in kg/cm2 (g)
80
70
Design Pressure
60 82 kg/cm2 (g)
50
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500 550
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
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

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

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 pre-
chamber.
¨ 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.

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

1680 50 K JM 001 Page: 97
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.

1680 50 K JM 001 Page: 98

1680 50 K JM 001 Page: 99

1680 50 K JM 001 Page: 100
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 pre-
heating.
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.

1680 50 K JM 001 Page: 101
¨ 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.

1680 50 K JM 001 Page: 102
¨ 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

1680 50 K JM 001 Page: 103

1680 50 K JM 001 Page: 104
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.

1680 50 K JM 001 Page: 105
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 Criteria - Tresholds Measurement
Rise up of max 10 °C/h; Stabilization at
T2 160-170 °C max for 6 days- Main Curve
Temperature CDQ Chamber inlet control parameter CDQ PLC Continuous
T4 Steam Drum Temperature Rise rate max: CDQ PLC
T? Boiler area Inlet of Boiler : Max 110 °C CDQ PLC
Drainage for EVAP
Slightly positive - max 10 mmH2O. To be
Pressure P1 CDQ Prechamber kept by provisional stack valve CDQ PLC Continuous
P3 Boiler inlet Negative pressure CDQ PLC Continuous
P4 Steam drum See Thermax Curve
P? Boiler area
Regulated by Main GCF - min 50000

Flowrate Circulation gas flow Nm3/h max 160000 Nm3/h CDQ PLC Continuous
LP steam flow
Level L4 Steam drum
Analysis Gas analyzers N.A in air drying CDQ PLC Continuous

Water steam drum

Temperature 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 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

1680 50 K JM 001 Page: 106
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)

1680 50 K JM 001 Page: 107
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.

1680 50 K JM 001 Page: 108
¨ 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

Rise up of max 100 °C/day; Stabilization at
300 °C - 450 °C and final stabilization at
T1 700 °C for Alakli boiling completion. Max
T 750 °C - Main Burner Heating Up Curve
Temperature CDQ TOP prechamber control parameter CDQ PLC Continuous
T4 Steam Drum Temperature Rise rate max: CDQ PLC
T? Boiler area T inlet of Boiler PLC
Super Heater 1SH
Super Heater 2SH
Evaporator
Economizer
External Sub-Eco
Steam outlet
Set point : 0 mmH2O (-2 up to +2 mmH2O)

Pressure P1 CDQ Prechamber Top - regulated by lower bleeding line PV CDQ PLC Continuous
P3 Boiler inlet Negative pressure CDQ PLC Continuous
P4 Steam drum
P? Boiler area
Regulated by Main GCF - up to minimum

Flowrate Circulation gas flow GCF flow up to 50000 Nm3/h CDQ PLC Continuous
Max 1500 Nm3/h (line design 2500
Nm3/h) - Burner max capacity 2500
Nm3/h - To be regulated according T1
COG Line flow temperature and heating up curve
AIR line Max 17800 Nm3/h
Boiler Feed water Water level at Drum: ??
Level L4 Steam drum Operation level +/- ? mm
Deaerator Operation level +/- ? Mm
Analysis Gas analyzers CO - O2 control CDQ PLC Continuous
Boiler Feed water Parameters to be analyzed: ?
Water steam drum Parameters to be analyzed: ?

1680 50 K JM 001 Page: 109

Temperature 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
Pressure Boiler inlet
Boiler outlet
Chamber inlet
Other T BY TL
Flowrate Main steam ?
Other T BY TL
Analysis COG Gas From Lab once /day
O2 -CO If necessary
Other T BY TL
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.

1680 50 K JM 001 Page: 110
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

1680 50 K JM 001 Page: 111
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,

1680 50 K JM 001 Page: 113
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 ≤ 200 °C

(mean, time average)
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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CDQ TECHNOLOGY

TATA STEEL LTD.

TATA CONSULTING ENGINEERS LIMITED

INDIAN PARTNE LARSEN & TOUBRO LIMITED

TITLE CDQ10 / CDQ11 COMMISSIONING MANUAL

PWIT NUMBER 1680 50 K JM 001 REV. 1

PERUGI AFI AEO

LARSEN & TOUBRO LIMITED

LARSEN & TOUBRO LIMITED

THE INFORMATION SET FORTH HEREIN CONSTITUTES PROPRIETARY TECHNOLOGY OF

THE RECIPIENT OF THIS DOCUMENT AGREES

NOT TO COPY OR REPRODUCE SAID DOCUMENTS IN WHOLE OR IN PART WITHOUT

NOT TO DISCLOSE SAID DOCUMENTS TO ANY THIRD PARTY WITHOUT WRITTEN

TO MAKE NO USE OF SAID INFORMATION OTHER THAN FOR THE PURPOSE OF

THIS INSTRUCTION MANUAL IS EXCLUSIVELY INTENDED TO AN USE BY TRAINED

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7.3 Hot Air Drying ................................................................................................... 104

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1. OVERALL PLANT COMMISSIONING

1.1 Basic safety instruction

1.2 Commissioning Plan

¨ Test of Electrical Panels and MCC.

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¨ First fill of oil for ALL equipment (when required)

¨ Check and preparation of materials, consumables as per Commissioning Manual

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1.3 Preparation of Commissioning – General Instructions

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1.4 Preparation of Commissioning – Cleaning, Flushing and Dryi

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Danger of damage to the machinery!

During flushing operations:

1.5 Preparation of Commissioning – Leakage / Pressure test

1.6 Preparation of Commissioning – Functional tests

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¨ Utilities available in sufficient quantity and quality.

Therefore, service water can be used as media for the execution of

While performing functional tests the full-load operation of the plant

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1.7 Preparation of Commissioning – Inertization

Danger of asphyxiation / poisoning!

1.8 Preparation of Commissioning – Try-out drains

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2. BASIC SAFETY INSTRUCTION

2.2 Intended use

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2.3 Safety notes and symbols

2.4 General safety remarks

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2.4.2 Safety signs: aim and selection

2.4.3 General measures about the plant

The following general measures shall be observed:

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2.5 Symbols and warning signs used in the manual

2.5.1 Hazard classes

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This combination highlights special user tips/ suggestions that can be

2.5.3 Environmental protection

This combination highlights key issues about environmental features or special

2.5.4 Personal protective equipment

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