Engineering Declaration Unit # 2 Jindal

7/27/2019 Engineering Declaration Unit # 2 Jindal

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GM (MTP)

UNIT # 2

2012-13

ENGINEERING

DECLARATION


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ENGINEERING DECLARATION

August 2012

FOR FINANCIAL YEAR 2012-13

1. Unit No: - 2 (250 MW BHEL Make)

2. Boiler License No: - CG-246

3. Boiler License validity (date) : 06.09.2012

4. Overhaul History (In reverse chronological order) for the past five years :

5. Unit Milestones / Major Event since inception:

S. No. Milestones / Events Data Remarks1 First synchronization (date) 07.03.2008

2 First commercial (date) 15.06.2008

3 BTL (Nos.) between two overhauls 3 OH 10 to OH 12

4 Trip (Nos.) between two overhauls 7 OH 10 to OH 12

S.No.

DescriptionOverhaul duration

Overhaulcategory

Operating Hrs.Since

prev. OH

Cumul.operating

Hours

Forced Outagesbetween two

overhauls ( nos )

Important& major

highlights

From To Total BTL Trip Total

1

Proposed

overhaul-

2012-13

01/09/

2012

17/09/

2012

17

days

Boiler &

auxilaries,

Turbine &

generator

Bearing & its

Auxilaries

16831.02 35118.794 3 7 10

2OH for FY

11-12

- - - - - - -

3OH For FY

10-11

01/09/

2010 at

3:22 Hrs

16/09/

2010

at

12:36

Hrs

15

days

9

Hrs

14

min

Boiler &

Turbine

auxilaries,

0 18287.774 - - -


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6. Unit performance History of Past Three years.

S. No. Parameters Previous 3 years

2011-12 2010-11 2009-10

1 Generation (MU) 2223.308 2141.018 2053.054

2 Availability (%) 99.27 94.90 93.77

3 Plant load factor (%) 101.24 97.76 93.75

4 Loading factor (%) 101.98 103.02 99.98

5 Total Generation Loss ( MU) 24.644 115.872 166.386

6 DM Make up (%) 0.44 0.48 0.70

7 Heat rate 2286 2293 2315

8 No. of BTL 0 2 6

9 No. of trips. 5 3 9

10 Total forced outage (%) 0.19 0.89 4.23

7. Boiler tube leakages detail since last overhauling.


4/16

SL.

NO

DATE &

DURATIONFAILURE LOCATION TUBE DETAILS TYPE OF DAM

1

16/11/10(11:43 HRS.)

TO 18/11/10

(12:43hrs)

(i) LHS STEAM COOLED WALL

TUBE NO-3 FROM REAR TO

FRONT.(ii) LHS STEAM COOLED

WALL TUBE NO-1&2 FROM

REAR TO FRONT AND LTSH

INLET HEADER SHH-9 LHS

END DUMMY

STEAM COOLED WALL STRAIGHT TUBE 3NOS EACH1 MTR

LENGTH. (MATERIAL SA 210 GRADE-A1 DIA 44.5X4.5MM

THICK).

ORIGINAL FAILUR

FINS WELDING AN

SECONDARY DAM

CAUSE DUE TO HI

PRESSURE STEAM

2

03/05/12

(12.23 HRS)

TO 04.05.12

(12.00 HRS)

STEAM COOLED WALL LEFT,

ELEVATION IN METRE 41

MTR, PRIMARY FAILURE- LHS

STEAM COOLED WALL TUBE

NO-3RD FROM REAR,NEAR

LTSH INLET HEADER.

SECONDARY FAILURE- LHS

STEAM COOLED WALL TUBENO-2ND FROM REAR,NEAR

LTSH INLET HEADER

ORIGINAL TUBE DIMENSION: TUBE OD-44.5 IN MM

THIICKNESS -4.5 IN MM, TUBE MATERIAL :SA 210 Gr-C

SECONDARY FAILED TUBE DIMENSION: TUBE OD 44.5 IN

MM, THIICKNESS - 4.5 IN MM, TUBE MATERIAL :SA 210 Gr-C

SUSPECTED ROOT

OF PRIMARY FAILU

FLUE GAS EROSIO

SECONDARY TUBE

FAILURES DETAIL:

SECONDARY FAILU

TO HIGH PRESSUR

CUT.

3

23.08.12

(15.32HRS TO

25.08.12

(07.23 HRS)

FURNACE WW LEFT,

PRIMARY FAILURE - FROM

CENTER OF WB-26,TUBE NO-

6 TOWARDS FRONT,

SECONDARY FAILURE - FROM

CENTER OF WB-26,TUBE NO-

7 TOWARDS FRONT,

ORIGINAL TUBE DIMENSION:TUBE OD-63.5 IN MM

THIICKNESS - 5.6 IN MM, TUBE MATERIAL :SA 210

GRC SECONDARY FAILED TUBE DIMENSION: TUBE OD 63.5

IN MM, THIICKNESS - 5.6 IN MM, TUBE MATERIAL :SA 210

GRC

PRIMARY FAILURE

ATTACHMENT WE

SECONDARY FAILU

TO HIGHPRESSUR

CUT


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8. Unit / Equipment Performance & Efficiency Evaluation Before Overhauling

Plant performance of Unit # 2 is as follows

S.No. Parameters Pre OH

1 Boiler Efficiency (%) 86.501

2 Corrected Boiler Efficiency 86.34

3 Gross Turbine Cycle Heat rate 2022

4 Corrected Gross Turbine Cycle Heat rate 2009

5 Gross Unit Heat Rate 2338

6 Corrected Gross Unit Heat Rate 2327

7 Heat rate Deviation 79

8 Accountable loss 54

9 Unaccounted loss 26

9. Efficiency Tests

1) Turbine Efficiency Test

a) Turbine Report Sheet

Sl.

No.Parameters Design Pre OH

1 Unit Load (in MW) 250 254

2 MS pressure (in kg/cm2) 150 145.6

3 MS Temp(in oC) 537 535.2

4 1 st Stage Pressure (in kg/cm2) 136.63 140.7

5 CRH Pressure (HPTurbine exhaust) (in kg/cm2) 39.57 40.66 CRH Temperature (HPTurbine exhaust) (in oC) 343 349.8

7 HRH Pressure (in kg/cm2) 35.62 38.2

8 HRH Temperature (in oC) 537 535.0

9 IP Exhaust Pr (in kg/cm2) 6.96 7.7

10 IP Exhaust Temp (in oC) 306.5 310.2

11 Extraction Pressure to D/A (in kg/cm2) 7.7

12 Extraction Temp to D/A 310.2

13 COND. TO DEARATOR Pressure(in Kg/cm2) 9.9

14 COND. TO DEARATOR Temp 120.3

15 COND. TO DEARATOR flow 612 621.4

16 BFP Suction temp(deg C) 163.5

22 MS Flow (in TPH) 758.5

23 FW Flow (in TPH) 757.48 758.5

24 Reheater Spray (in TPH) 0 25.3

25 HPH6 FW O/L Temp(in oC) 245.9 247.2

26 CRH Flow Calculated 665.8 701.7

27 Condenser Vacuum -0.906 -0.902


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b) Turbine Performance Indices

1 Gross Turbine Cycle Heat rate (in Kcal/kwh) Design 1951

2 Gross Turbine Cycle Heat rate (in Kcal/kwh) 2022

3 Corrected Turbine Cycle Heat rate (in Kcal/kwh) 2009

4 Deviation (Corrected Design) (in Kcal/kwh) 58

c) Cylinder efficiency

1 Parameters Design Pre

2 HP Cylinder Efficiency 86.66 86.54

3 IP Cylinder Efficiency 91.90 90.52

2) Condenser Performance

Sl.

No.Description Unit

Date

Design Pre OH

1 Load MW 250 254.0

2 Condenser pressure Kg/cm2 -0.906 -0.897

3 Condenser back pressure mbar 101.13 98.31

4 Optimum back pressure mbar 91.6 93.05

5 Corresponding Saturation Steam Temperature Deg C 44 45.25

6 CW inlet Temperature Deg C 33 31.30

7 CW outlet Temperature Deg C 41.5 40.728 Optimum CW rise Deg C 8.5 8.50

9 Actual CW Rise Deg C 9.42

10 Optimum TTD Deg C 2.5 4.50

11 Actual TTD Deg C 4.53

12 Back pressure due to CW inlet (6+8+10) mbar 92.54

13 Back pressure due to CW flow & CW inlet (7+10) mbar 97.04

14 Variation due to CW inlet temp mbar -0.51

15 Variation due to CW Flow mbar 5.50

16 Variation due to air/ dirty tubes mbar 3.27

17 Total Variation mbar 10.77

18 Number of Vacuum Pumps in service nos 1

19

CONDENDER DUTY

HEAT ADDED MS=FlowMS*(hMS-hFW) Kcal/kg 425758305

HEAT ADDED CRH=FlowCRH*(hHRH-hCRH) Kcal/kg 73088791

HEAT ADDED RH=FlowCRH*(hHRH-hATT) Kcal/kg 15026650

TOTAL HEAT ADDED 513873746

HEAT LOSS THROUGH RADIATION kW 254

Pgen kW 254000

Pgen Losses kW 2540


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Total Heat lost 256794

CONDENDER DUTY Kcal/hr 293030906

20

CW FLOW= Cond Duty /((Cwout- Cwin)xdensityx

Cp) m3/hr 31104

Outer dia OD mm 29

Tube thickness (t) mm 1

Cross -Sectional area mm2 590Total No of Tubes nos 15664

21 WATER VELOCITY IN CONDENSER TUBE m/sec 1.870

3) Boiler Efficiency

ParametersDate 08.08.2012

Design Pre OH

Unit Load 250 254

Steam Flow 740 758.5

COAL FLOW 157 178APH GAS INLET TEMP 340 246.0

APH GAS OUTLET TEMP 132 138.7

AVG I/L PRIMARY AIR TEMP 34 34.01

PRIMARY AIR FLOW 239 291.79

AVG O/L PRIMARY AIR TEMP 310 296.8

AVG SECONDARY AIR I/L TEMP 34 32.1

AVG SECONDARY AIR O/L TEMP 320 302.1

SECONDARY AIR FLOW 571 520.8

AH INLET O2 % 3.5 2.7

AH OUTLET O2 % 5 5.4

AH OUTLET CO2 % 15.4 15.8AH OUTLET CO % 75 12

UNBURNT IN FLY ASH 0.6 0.3

UNBURNT IN BOTTOM ASH 1.5 1.33

AMBIENT AIR TEMP DRY 34 27

AMBINT AIR TEMP WET 28 25

AMBINT AIR TEMP RH 60.0 85

Proximate Analysis Result

Total Moisture 12 13.0

Ash 39 39.2

V.M 22 23.0

FC 27 24.9

GROSS CALORIFIC VALUE 3600 3507

Heat Losses (%) Design Pre OH

UNBURNT CARBON LOSS 1.2 0.412

HEAT LOSS DUE TO HEAT IN DRY FLUE GAS 4.211 5.235

HEAT LOSS DUE TO MOISTURE IN AS FIRED FUEL 2.067 2.314

HEAT LOSS DUE TO MOISTURE FROM BURNING OF

HYDROGEN4.309 4.048


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HEAT LOSS DUE TO MOISTURE IN AIR 0.16 0.175

HEAT LOSS DUE TO SURFACE RADIATION & CONVECTION 0.22 0.22

HEAT LOSS DUE TO RADAITION & UNACCOUNTED 0.54 0.74

HEAT CREDIT( HEAT EQI. OF POWER) -0.165

HEAT LOSS DUE TO MILL REJECT 0.020

MANUFACTURE MARGIN 0.5 0.5

TOTAL HEAT LOSS 13.207 13.501BOILER EFFICIENCY 86.79 86.50

CORRECTED BOILER EFFICIENCY 86.34

4) APH Performance

Parameters DesignPre OH

Pass A Pass B

O2 I/L (Oxygen at APH Inlet) 3.76 3.5 3.5

O2 O/L (Oxygen at APH outlet) 5 5.7 5.2

PA inlet Temp (Tpai) 34 37.5

PA outlet Temp (Tpao) 314 296.8

PA flow 238.6 301.4

SA inlet Temp (Tsai) 34 32.0

SA outlet Temp (Tsao) 319 302.1

SA flow 570.7 520.8

Weighted Avg intet Air temperature (Tai) 34 34.0

Weightyed Avg outlet Air temperature (Tao) 317.5 299.5

Flue gas inlet temperature (Tgi) 348 348.5 341.5

Flue gas outlet temperature (Tgo) 132 136.4 137.4

Flue gas outlet temperature with no leakage (Tgnl) = AL xCpa x (Tgo - Tai)/(100x Cpg) + Tgo; where Cpa(specific

heat of air) = 1 and Cpg (specific heat of gas) = 0.993

138.9 151.1 152.6

A/H LEAKAGE ( in %) 6.98 14.28 10.95

A/H Gas side Efficiency (GSE) 66.60 62.77 61.46

A/ H - X Ratio 0.74 0.74 0.71

5) ESP Performance

ParametersDate 28.08.2012

Pre OH

Design Pass - A Pass - B

Load 250 256.5

ESP I/L Draft(mmwcl) -203 -167.89 -167.43

ESP O/L Draft (mmwcl) -249 -296.18 -296.50

Pressure Drop 46 -128.29 -129.07

ESP I/L Temp(oC) 132 128.17 128.49


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ESP O/L Temp (oC) 122 113.72 112.01

Temperature Drop 10 14 16

Opacity 50 47.2

Fields not in Service NIL

ID Fan - A Current 190.53

ID Fan - B Current 191.88

6) Cooling Tower Performance

Sl.No. PARAMETERSDate

Design Pre OH

1 No of cells 14 13

2 CW O/L Temp 42 42

3 CW I/L Temp 33 32.3

4 DRY BULB TEMPERATURE 29.2

5 AMBIENT WET BULB TEMP 28.5 27.13

6 APPROACH(A) = Cwi - WBT (in oC) 4.5 5.2

7 RANGE(R) = CWo - Cwi (in oC) 9 9.6

8 EFFECTIVENESS(E) = (RX100)/ (R+A) 66.7 65

9

TOTAL WATER FLOW RATE CALCULATED

(CR)=(CW+ACW)40000 33578.08

10

EVAPORATION LOSS = CR x (Cwo- Cwin) /675 in

M3/hr

520at 90% RH

design479

11 COOLING CAPACITY in Kcal/Hr 360000 323577

12

CYCLES OF CONCENTRATION = TDS in CW/TDS in

makeup8 6.67

13

MAKE UP WATER CONSUMPTION = Evap Loss

/(COC - 1) in M3/Hr74.29 84.55

14 CW Flow to each Cell 3077 2583


10/16

10. Scope of work

BOILER

PRESSURE PARTS

Complete Boiler water washing, wall scrapping & buffing.Erection & Dismantling of Quick Erect Scaffolding in first pass up to roof tubes at every 2mt

elevation including PSH

Thickness survey of tubes

Erection of scaffolding and platform in LTSH Terminal Tubes, Re-heater (both banks), Screen

Tubes, Hanger Tubes at every 2.0 mtr. elevation and complete platform below Economizer.

Pent house & dead chamber cleaning

DP test of weld joints & header stub and attachment welding.

Shifting, Dismantling, Erection & Alignment of Eco coils (Upper& Lower )

Lifting/Lowering of coils (lower & upper) for inspection

Welding of HP tubes up to 76.1mm dia.

Strengthening of boiler tubes by weld overlay.Refurbishment of header by weld overlay

Fabrication of HP bends up to 76.1mm dia.

Alignment of coils (PSH, RH, FSH, LTSH, Eco)

Fixing of protection shields /shrouds

Fin/skin casing welding by tested welder

Application of Plastic Refractory

Application of insulation & cladding sheet

Drum cleaning and inspection

Wall blower distance setting & sleeve fitting

Servicing of buckstays, manhole, peephole ( servicing of all buck stay pins, boiler expansion

indicators, manholes, peepholes, tie rod of dog house & pent house header hanger supports.)Repair & Re-installation of bottom seal plate and Woven Wire Mesh

Replacement/repair of fuel burners replacement of 24 Nos. coal nozzle , repairing of all oil &

air bucket, servicing of tilting mechanism ,repairing of wind box & servicing of SADC.

Cleaning of 12 Nos. coal pipes with water jet. Servicing of oil, air & steam atomizing lines valve

firing floor.

Reversal of coal pipe orifice.

Rotation of coal pipe (2 - 6 mtr. length)

Replacement of coal pipe

Repairing of coal pipe by patch welding of 500mmx500mm piece

Inspection and Servicing of coal pipe coupling

Alignment of coal pipe

Inspection/repair/replacement of coal pipe bends

Servicing of coal burner isolation gate.

Cold Air velocity Test

BOTTTOM SEAL TROUGH

Inspection of seal plates & thorough cleaning of seal trough

Inspection & checking of quenching nozzles & its direction

Repair/ Replacement of SS Mesh & Bottom Seal plate AT BAH


11/16

VALVES

Overhauling Of HP Valves - Drain & Vents, Root Valves

Overhauling & Pressure setting of safety Valve SV1 to SV5

FUEL FIRING SYSTEM (COAL & OIL BURNERS, SADC )

Replacement of 24 nos coal nozzle ,servicing & alignment of burner tilts

Repairing of Wind Box & Servicing Of SADC & its synchronized movement

Condition checking of oil & air compartments

Healthiness checking of air guide vanes inside wind box

Inspection of all attachments in the burner zone near transition tubes to check whether wind

box is properly loaded on the water wall tubes & no attachment is missed out during

replacement of burner transition tubes

Thickness measurements of coal pipes

Condition based replacement of coal pipes

Inspection of elbow/bend , orifice & victaulic gasket randomly.

Servicing of knife edge gate valves for coal nozzle

APH A & B

All Baskets to be taken out &cleaned with High pressure water jet. Templates to be made for

covering the cleaned baskets so that foreign material does not fall into the basket.

Renewal of Outboard baskets (48 nos.) / APH

Seals And Baskets Inspection & Arrangement for Basket Cleaning, Seal setting (replacement of

damage seals)

Guide & Support Bearing, rotor post aluminum seal opening & inspection,

Hot end & cold end rotor post seal repair/replacement & kao wool packing

Lub oil system servicing of support & guide bearing

Guide & support bearing oil flushing & oil changing

Attending hot air leakages in guide bearingAir heater soot blower servicing & angle setting

Inspection of Gear box, fluid coupling & oil changing & realignment.

Servicing of Air motor

Support & Guide Bearing alignment after seal setting

Repairing of APH duct from GD1 & 2 to APH Hopper

Checking of healthiness of fire fighting system- replacement of eroded headers,

cleaning/replacement of nozzles

DUCT & DAMPERS OVERHAULING

Cleaning, Inspection and thickness measurements of ducts

Repair , replacement of eroded bracings, duct plates & guide vane plates/Expansion Bellowsof PA & FD , ESP I/L & O/L ducts with SAIL HARD/ SELMA STEEL

Servicing & repair of all dampers and gates along with seals

Replacement of eroded guide vanes

Checking of the operating mechanism of all the dampers & gates

Checking of the healthiness of the blower

Practices to be followed during Overhauling of Boiler

Steam/air blowing of new tubes before installation

Sponge ball test of new coils/bends to be done before installation


12/16

All vertical tubes to be cut with grinders only

Immediate capping of tubes to be done after cutting

Deployment of tested cutter for tube cutting

Deployment of tested HP Welders for welding of joints.

All attachment welds to be done by tested welders

Attachment welds to be done by 2.5mm size electrodes only

All supports / clamps to be restored to original

FANS

Inspection, repair & maintenance of PA Fans, FD Fans, ID Fans, Seal Air fans.

COAL MILL & FEEDER.

Replacement of Grinder Roller of Mill 4A & 4C

Replacement of Bullring Segment of Mill 4A, 4B, 4C & 4D

Replacement of Clamping Ring of Mill 4A, 4B, 4C & 4D

Hard facing Inside Mill & JOC

Servicing/Replacement of of Journal Pressure Spring

Replacement/Servicing of Classifier Vane Assembly.

ESP

Thorough internal inspection of ESP electrodes to locate defects and repairing.

Cleaning and inspection of shaft insulators, support insulators and replacement of any

damaged insulators. Screen tube and Field suspension rod.

GD Test to be done

TURBINE

Overhauling of LP Turbine Module

Replacement of Hydrogen Seal Rings of Generator.

Overhauling of Generator & Exciter

Inspection of Bearing Nos. 1 to 7 and H2 Seal Ring.

Overhauling of MOP, MS Strainer (LHS), HRH Strainer (RHS), PHE A & B, CEP - 2A, 2B & 2C-

Provided we receive the Dummy sleeve reqd. for modification of CEP.

Servicing of Turning Gear, HPSV, HPCV, IPSV, IPCV & its Servomotor, HPBP Valves, HPBP Spray

valves, Butterfly Valves, Air Release valves.

Checking of Governing Characteristics

Cleaning of BFP & Booster pump suction strainers, De-aerator, FST, OCST & DMCW Tank, Hot

well, ACW Strainer Elements, Cooling Tower basin

Transferring of Oil in MOT to COT, Cleaning of MOT and again transferring of oil from COT to

MOT.Condenser Tube cleaning by Bullet Shot Method and applying of Chemical Resistant Coating

in Condenser tube sheets & water box

Carrying out Condenser Flood test, Air/H2 leak test of Generator, Hydro test of H2 & Exciter

Coolers

CW Duct Butterfly valve inspection and servicing

Attending identified leakages and defects booked by Operation dept.

CT Basin Cleaning, Cooling Tower nozzles & drift eliminators cleaning, repairs & replacement


13/16

Electrical

Overhauling of Generator Generator overhang portion NFT Test & Inspection.

Exciter & PMG Dismantling, inspection & testing.

NGR, NGT & SPVT inspection, tightness checking & testing.

Preventive maintenance of Gen Aux Panel- ECB, CFA & CTE02 Panel.

Transformer Overhauling GT General Checking & OLTC inspection, UAT A&B oil filtration,OLTC inspection, ST2- OLTC inspection & general checking. Testing of GT , ST & UAt-2A &2B.

Unit & station auxiliary transformers cleaning, inspection, tightness checking & testing.

6.6 KV HT SWITCHGEAR(5 Nos of MAIN PLANT & BOP) - inspection & cleaning of bus bars &

feeders, connection tightness of power and control cables, sealing of spare holes ,inspection

of CT's and PT's.

415 V LT SWITCHGEAR (17 Nos. of MAIN PLANT & BOP)- inspection & cleaning of bus bars &

feeders, connection tightness of power and control cables, sealing of spare holes ,inspection

of CT's and PT's.

H.T.MOTORS OVERHAULING (15 nos )- ID Fan A&B, FD Fan A&B, PA Fan A&B, Coal Mill

A,B,C,D &E, 1 BFP, CEP- A, B&C. Cleaning, varnishing, painting, bearing inspection &

replacement and testing.

LT MOTORS OVERHAULING (81 Nos.) - Cleaning, varnishing, painting, bearing inspection &

replacement and testing.

Wall & soot blowers cleaning, inspection, motor bearing replacement if required.

MOV Actuators overhauling Cleaning, inspection, grease & oil replacement.

AVR cleaning, inspection, tightness, field breaker alignment testing, & Dynamic Testing

GRP-Cleaning, inspection, tightness, relays testing, annunciation checking.

ESP - BAPCON, RAPCON Panel, Rectifier Transformer Overhauling &testing, PMCC,MCC & Dry

transformer overhauling.BATTERY AND D.G. SET-Capacity test of 220 V UNIT-2 Main Battery & UPS battery, Battery

charger cleaning, tightness & inspection

220 KV Switchyard bay: Breaker, CT, Isolators general checking/ testing/ maintenance.

C&I

TG AREA

Cleaning of field equipments, JB's and ensuring the tightness of all connections.Checking and calibration of all critical instruments related to plant ,equipment tripping,

interlock and efficiency analysis.

Checking and calibration of control valves and hydraulic actuators.

Checking of TSI pick up response and calibration.

Servicing of UPS & ACDB

To install and commission electronic level switch in CRH.

Checking of protection interlock of turbine and its auxiliaries

DCS storian upgradation and HMI software setting and checking.


14/16

Cleaning and checking of the DCS cards.

Flow nozzle of LPBP spray to be shifted before MOV.

To Replace HP exhaust thermocouples.

To replace MOT level transmitter with radar type LT to improve reliability and accuracy.

To install isolation valve in the downstream of CEP vent solenoid valve.

To shift orifice plate of DM makeup flow from downstream to upstream of CV.

Skin type RTD to be installed in BFP recirculation line to detect RC valve leakage.

RTD to be installed in place of temperature switch in Vacuum pump for improving condenser

performance.

ATRS/ATT establishment to be checked and to be made operative.

BOILER AREA

To check the overall instrumentation of HFO Station (FM,HOTV &HOFCV), LDO & Air Station

(FM,LOTV&LOFCV) & Station for Atomising Steam at Operating Floor

To check the operation of Oil Burner - AB Elevation (AANV,ASNV,HONV & LONV) and for CD &

EF Elevation (AANV,ASNV & HONV)

Servicing/checking of HEA Spark Rod/Igniter advancement / Flame Scanner functioning at all

elevations

To check/replace the T/C's of HOT end & cold end of APH-A&B, RTD of guide bearing of APH.

To check/inspect & Calibrate both Oxygen probes, PA Header Pressure Transmitters (03 Nos.)

& Switches (05 nos.), Furnace Pressure switches (06 NOS)

Cleaning & Calibration of SADC Power cylinders (56 Nos.)

Cleaning & Calibration of all Power cylinders for ID, FD, PA, HAD,CAD, HAG & Burner Tilt (Total

30 Nos.)

Checking and calibration of all critical instruments related to plant equipment tripping,

interlock and efficiency analysis.

All auto control loops performance checking and fine tuning.

AHP AREA

ESP level probe checking.

ESP vacuum transmitter calibrationSlurry pumps interlock & protection checking

Overhauling of all Power cylinders (Total 90 Nos)

Buffer hopper purging solenoid valves orientation to be changed from horizontal to vertical.

ASH HANDLING SYSTEM

Bottom Ash Hopper Refractory work.

Seal trough cleaning and repairing.

Inspection, Servicing and Assembly of fluidizing pads (128 Nos.)Replacement of all gaskets between hopper to M.S. adaptor & M.S. adaptor to knife gate

valve

Inspection, Servicing and Assembly of all MHV (72 Nos.) of ESP, Duct and APH hoppers and

their segregating valves (29 Nos.)

Inspection, Cleaning and Replacement of worn out parts of all collector towers.

Inspection , Replacement of worn out parts of rotating segregating valves of all Air lock

vessels.

Removal, Inspection, Replacement & Assembly of fluidizing pads of buffer hopper & air lock

vessels


15/16

Inspection, Replacement of damaged bag, cage of bag house

Inspection & replacement of worn our parts of feed gate assemblies, hydro ejector.

Dismantling of flushing apparatus, inspection & replacement of gaskets, nozzles, pipe, fittings,

valves and reassembly of flushing apparatus in Economizer Hopper

11. Improvement & Modification Work

TMD

Modification of CEP. Installation of dummy stage in place of 2nd Stage, for existing3 No. CEPs.

Corrocoat Coating of CW & ACW Pumps Hydraulic passage of Unit#02.BMD

Application of Plastic Refractory. Burner nozzles to be modified and replaced during Overhauling.

C&I

Relocation of temperature element of after reheater desuperheter to avoidmeasurement error.

Flow nozzle of water injection flow of LPBP to be shifted before motorized valve asexisting installation does not cover flow through motorize valve .and to avoid unit

tripping in case of failure of pneumatic valve.

To replace head type RTD/Thermocouples with head less ones in critical areas likeexciter hot air temperature & seal oil temperature etc.

To replace MOT level transmitter with radar type LT to improve reliability andaccuracy.

Installation of RTD in place of Temp switches in Vacuum pump for monitoring andcontrol of temperature and improving condenser performance.

Provision for remote monitoring of HPBP system oil pressure and control of HPSUpump.

BFP trip contact of dearator level low to be derived from transmitters in addition toswitches to improve reliability.

To install isolation valve in the downstream of CEP vent Solenoid valve. To shift orifice plate of DM make up flow from downstream to upstream of CV to

avoid measurement errors.

UCP,ATRS & ATT establishment. Skin type RTD to be installed in BFP recirculation line to monitor RC valve passing. Buffer Hopper purging SOV'S Orientation to be changed from horizontal to vertical to

improve reliability.

To install & commission electronic level switch in CRH. Main Steam temperature low trip contact to turbine to be derived from soft to Hard

as an endeavor to improve reliability.

Relocation of Local Vibration Indicator Junction Boxes for ID, FD&PA Fans.


16/16

ELD

Auto Bus transfer scheme at CTPMCC in UNIT-2 6.6 KV HT Board H.T. Motor tripping from Bus PT at main plant in UNIT-2 Redundant Power supply arrangement of AVR For unit -2 Provision of all H.V. motors over load alarm of unit -2 at CCR LVS Generator SPVT all voltage transformers of Prayog make shall be changed with Pragati

make voltage transformer total nine numbers

6 Amp MCB to be provided in place of low rated MPCB in motor feeder module

12. Pending defect & Opportunity Based jobs-

Pending defects are available on line, being attended and updated daily. Pending defect list to be taken before one month of unit shut down.

13. Justification/Evaluation of Overhauling

1. For Boiler license renewal, validity is up to 06/09/2012. The Boiler license is to berenewed up to for further two years duration.

2. During Annual Overhaul essential activities shall be carried out for safe and reliableoperation of the unit for next two years.

3. Overhauling of LP Turbine Module & Generator to be done.4. Due to Furnace Fouling Flue gas Temperature, SH spray & RH spray are of higher side,

which shall be reduced by High pressure Jet cleaning, scrubbing of Boiler etc. This will

reduce the Heat rate losses and improve the plant efficiency.

5. Due to air ingress in the boiler and ducts, ID fan currents is on higher side, which can bereduced by thorough inspection of ingress points in BA hopper, Seal trough area,

Replacement of rope gaskets in ESP manhole doors.

6. Air Heater Air ingress is on higher side, Air side gas side efficiency is also poor whichrequires APH seal setting, cleaning of basket and APH hot water washing.

7. Cleaning of ESP during shutdown will not only improve the performance but willbenefit help to meet the requirements of pollution norms.

8. Condenser cleaning by high pressure bullet jet and condenser flood test during OH willalso help to reduce any type of losses in performance of unit. Cooling Tower cleaning

during AOH will also benefit us for condenser performance improvement.

9. Passing of High pressure Energy drains has been already identified, which shall beattended during OH.

Documents

Engineering Declaration Unit # 2 Jindal