VEDANTA LIMITED, LANJIGARH

Integrated Management System

SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

1. PURPOSE : SMP For Opacity Meter

2. SCOPE : Boiler #1, 2, 3 & CEMS
3. RESPONSIBILITY : Instrumentation Engineer
4. TOOLS : DMM, Screw driver & Spanner set, paint brush, Zero Point Reflector
5. MANPOWER : Technician-1,Helper-2
6. DURATION : 2 Hour (PM), 4 Hour (Calibration)
7. PROCEDURE:

DURING SHUTDOWN MAINTENANCE

7.1. Take the PTW against PM order.

7.2. Clean the exterior of the Trans-receiver unit, reflector unit and the control unit with cotton cloth.
7.3. Open the cover of the electronic unit and clean the interior by using the paint brush.
7.4. Check the cable termination, if required tightens the mounting screws and cable terminations.
7.5. Check the input power supply and the grounding properly with DMM.
7.6. Observe the display unit for any error in the system. If any error comes then troubleshoot the system by
following the troubleshooting section from OEM manual.
7.7. Observe the reading in the electronic unit and verify the same with DCS display. If any deviation found
then check the output mA current with DMM.
7.8. Isolate the system Power supply and take out the both Trans-receiver and reflector unit by the help of the
spanner. Keep them in a cool ambient and allow lenses to cool down to the ambient temperature.
7.9. With a soft clean cotton cloth slowly and carefully clean the lenses of both the Trans-receiver unit &
reflector unit.(Improper cloth or carelessness during cleaning may lead to scratches in the lens)
7.10. After this please mount back the Trans-receiver unit and reflector unit carefully.
7.11. Connect the instrument air connection and maintain the air pressure in the nearer to 1.5 Bar and also
ensure the proper air supply to both the Trans-receiver and reflector units.
7.12. Normalize the system Power supply and follow the below steps for the proper alignment of Trans-
receiver & reflector units.

a) To align the transceiver, look through the alignment sight on the side of the transceiver housing.
Make sure the reflector is closed on the reflector side.
b) Then by adjusting the nuts on the stack flange of the transceiver side as shown in the previous
figure, move the transceiver in the horizontal and vertical directions until the reflector image is
centered in the “bulls eye” of the alignment sight.
c) Please note that as the transceiver is moved horizontally, the image in the alignment site will move
vertically.

Revised By : Rakesh Ranjan Das

Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera
 VEDANTA LIMITED, LANJIGARH
Integrated Management System
SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

On longer-range systems the image in the alignment sight may not appear very bright. It may be
helpful to cup your hands around the eye piece of the alignment site to block the ambient light
when aligning the transceiver.

d) The adjustment nuts should compress the spring washers to the point that the transceiver (or
reflector) is stable. The spring washers should not be completely compressed, then there would be
no room for further adjust the alignment.
7.13. Ensure proper covering of the Trans-receiver unit, reflector unit and the control unit.
Revised By : Rakesh Ranjan Das
Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera
 VEDANTA LIMITED, LANJIGARH
Integrated Management System
SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

7.14. Update the check list & cancel the PTW.

DURING CALIBRATION

7.15. Take the PTW against Calibration order

7.16. Set up the transceiver and reflector in a dust-free room (or use a measuring pipe) to set up the monitor to
the maximum range of the reflector. Make sure the flanges on the transceiver and reflector are parallel.
Clean the optical surfaces (exit windows) with a soft cloth designed for optics.
7.17. Next, open the four hasps on the transceiver head and swing it open. With a 4 mm allen wrench, remove
the six screws that hold the cover in place. Close the transceiver and latch it shut with the hasps.
7.18. In the transceiver, push switches S2 and S3 into the “ON “position, in the multiple switch S4, switch
S4/6 should be in the “OFF “position and the three=position switch S5 should be in the center (enabling
data entry).
7.19. Power up the transceiver and AW controller (Plug St. 1). Line 1 of the LCD display should read: ZERO
EXT. CALIB.

7.20. Optically align the transceiver. (Follow the step 7.11)

7.21. Return switches S2 and S3 to the lower, OFF  position, then push switch S5 toward the front of the
monitor (for calibration cycles) until the yellow LED blinks. Return switch S5 to the center position; the
yellow LED should continue blinking for the rest of the basic set-up procedure. The red LED should be
constantly lit, indicating that data entry is enabled. The LED current will be calculated against the external
measurement path. The lower line of the LCD display should be working and segment four will display the
LED current value. The displayed value should be between 700-1000. A value of 4000 corresponds to an
LED signal of approximately 100 mA.
7.22. If S4/6 on the S4 switch is returned to the ON  position before the basic set-up is completed, any
previously recorded filter audit (linearity) data will not be erased.

Revised By : Rakesh Ranjan Das

Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera
 VEDANTA LIMITED, LANJIGARH
Integrated Management System
SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

7.23. After the LED current is set, the monitor will determine the amplification of the comparison normal light
beam. The lower line of the display will be active and segment three will show the amplification factor.
This should be in between 10 to 50.

7.24. After the basic set-up is complete, a calibration cycle will run (the yellow LED will go out). To prevent
any further changes to the monitor set-up, put switch S5 to the back (the red LED will extinguish). On
switch S4 put S4/6 in the ON  position. If S4/6 on the S4 switch was already returned to the ON 
position before the basic set-up is completed, any previously recorded filter audit (linearity) data was
preserved.

7.25. Once the calibration cycle has been completed (the yellow LED will not be lit), disconnect the transceiver
and controller (power off) and replace the cover with the six screws.
7.26. Carryout the steps 7.9 to 7.11.
7.27. Fix the calibration tag.
7.28. Return the PTW.

8. QUALITY:

8.1. All the parameters, activities are maintained within prescribed limit. (Accuracy: ±1.0 % FSD)
8.2. Any deviation from the norm is recorded and corrective action is taken accordingly.

Revised By : Rakesh Ranjan Das

Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera
 VEDANTA LIMITED, LANJIGARH
Integrated Management System
SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

9. ENVIRONMENT:

Not applicable

10. ENERGY:

Not applicable

11. OHSAS:

11.1. Ensure PPE, Helmet, adequate lighting near the work place.
11.2. Ensure healthiness & safety of the entire activities with respect electrical system
11.3. Ensure deployment of a group of people (2 or more) while carrying out job in an isolated or deserted
place or in night shift.

12. RECORDS: VLL/CPP/INST/FILE/05

Revised By : Rakesh Ranjan Das

Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera
 VEDANTA LIMITED, LANJIGARH
Integrated Management System
SMP description: SMP For Opacity Meter

Version No: 03 Department: Power Plant SMP No: 2201/INST/WI-08 Revision No: 01 Revision Date:

Document Revision History

VERSION REVISION
DATE CHANGE SUMMARY
NUMBER NUMBER
Version changed:
1. Company name changed(VAL- SSL)
11.09.2013 01 00
2. Indication of Abbreviations, Details of document at the
footer
Version changed:
00
Document format changed.
07.06.2014
02 Content Addition: Equipment safety, Bibliography, Man power
01
required.

26.11.2014 02 SMP for PM & calibration included in procedure.

Version Changed:
10.05.2015 00 1. Company name changed from SSL to Vedanta Limited
2. Company logo changed.
03

23.05.2021 01 Plant code 5200 has changed to 2201 in SMP No.

Revised By : Rakesh Ranjan Das

Prepared by : Amarendra Sahoo Date of Issue : 10.05.2015
Checked By : P.K. Singh
Date of preparation : 08.04.2008 Date of review : 23.05.2021
Approved By: Susheem Kumar Behera