Shutdown Report July 10

8/8/2019 Shutdown Report July 10

1/21

SHUT DOWN REPORT

JULY 2010

SAMRUDDHI SITE

1 X 12.5 MW THERMAL POWER PLANT

Shutdown from : 05 July 2010 - 00:10 Hrs

Synchronized at : 23 July 2008 - 20:28 Hrs


2/21

CONTENTS

DESCRIPTION PAGE No

1) MAJOR EVENTS : 3

2) ACTIVITIES ON BOILER : 5

3) ACTIVITIES ON ASH HANDLING SYSTEM : 8

4) ACTIVITIES ON COAL HANDLING PLANT : 9

5) ACTIVITIES ON TURBINE AUXILIARIES : 9

6) ACTIVITIES ON RO/DM & COOLING TOWER : 10

7) OTHER ACTIVITIES : 11

8) SAFETY VALVE SETTINGS REPORT : 12

9) DISPLACEMENT / SPEED, VIBRATION / SENSORS

INSPECTION / MEASUREMENT REPORT : 13 - 20

Hofincons Samruddhi site - Shutdown report July - 2010 2


3/21

MAJOR EVENTS

Fabrication & Erection of over bed fuel feeding chute for 2nd & 3rd Compartment.

DCF#1, #2, #3 & #4 new chain replaced.

DCF #1, #2 & #4 - DE & NDE Shaft with sprockets and bearings replaced.

ID Fan DE & NDE bearing and Plummer block renewed.

PA fan #2 DE & NDE bearings renewed.

FD Fan DE and NDE bearing renewed.

Boiler all bed drains below and pipe renewed.

All vertical and Horizontal PA line pipes renewed and extra gate additionally

added

Reverse Shuttle Feeder conveyor Belt renewed.

BFW Pump #2 DE & NDE Bearing hosing, stuffing box and bearing renewed.

Ash silo bag filter inspection and renewed.

CHP Dust extraction bag filter inspection and renewed.

CHP Dust extraction hopper modification.

CHP Bucket elevator discharge chute renewed.

Cooling tower fan # 1 gear box renewed.

TPP & DG all HT panel and LT panel, GCP, GRP panel relays testing coordination

done.

TPP All LT Breakers servicing coordination done.

TPP All HT Breakers servicing and O/G terminal side inspection work done.

TPP to DG-2 DSLC panel cable termination, programming and commissioned work

U/p



4/21

TPP Aux TR-1&2, ESP TR-1&2 Oil filtration and checked Oil BDV test coordination

done.

TPP Main Battery Bank and Stand by Battery Bank Load test coordination and

checked found working normal.

DG All HT Breaker servicing work done.

TPP Alternator, Exciter, PMG cleaning and inspection work done.

TPP Alternator LASCPT panel, NGR panel, GCP, GPR, AVR panel cleaning and

inspection work done.

Turbine major O/H Bolt heating equipment power cable, JB fixed and termination

work done.

All Boiler & Turbine area MOV valves and actuators cleaned and signal cables

terminations checked and operation checked from DCS Found normal.

All local Instrument JBs cleaned and terminations checked found normal.

All vibration probes & speed probe in Turbine and Alternator side removed for

major O/H then fixed back found all probes are normal the gap voltage measured

is enclosed for reference at Page No : 14 - 21

All Boiler & Turbine aux. system PGs and TGs calibrated and found normal.

Five numbers of bed thermo well and all thermocouples renewed.

All Control valves & RPCs calibrated as well as stroke checked found normal.

All transmitters were calibrated found all in order.

TPP UPS battery cell voltage checked and found ok.

FD, PA & ID vibration probe and Temperature sensor serviced and fixed back.

All FD & PA line power cylinders & all bleed valves and SOVs serviced and fixed

back.

MOV valves were stroke & found ok



5/21

ACTIVITIES ON BOILER

Remaining fuels emptied from Lignite & Coal bunkers and all bunker lumps

removed.

RSFD #1 conveyor Belt renewed.

All DCFs were cleaned.

All DCFs were provided with new rail plates.

DCF #1, #2, #3 & #4 new chain provided.

DCF #1, #2 & #4 renewed DE & NDE Shaft with sprockets and bearings.

DCF # 3 DE and NDE both bearing renewed. Boiler PA drain #1, #2, #3 and #4 compartment all pipe line renewed and

extra gate 16 nos provided.

Boiler PA horizontal #1, #2, #3 and #4 compartment all pipe line from Air

box to Mixing nozzle renewed.

Boiler- compartment #2 and #3rd OBF chute renewed.

Boiler MCC panel bus, cable chamber and all feeders maintenance work done.

All Lignite and Coal Pocket feeder motors DE & NDE side bearing renewal and

winding cleaning varnish applied.

Phase to Earth IR Value WR Value

#1 100 meg 11.1 /ph

#2 100 meg 11.3 /ph

#3 100 meg 11.5 /ph

#4 100 meg 11.4 /ph

#5 100 meg 10.2 /ph

#6 100 meg 10.9 /ph

#7 100 meg 10.5 /ph

#8 100 meg 11.4 /ph

All Drag Chain Feeder motors DE & NDE side bearing renewal and winding

cleaning varnish applied.

Phase to Earth IR Value WR Value

#1 100 meg 9.1 /ph

#2 100 meg 9.3 /ph#3 100 meg 9.5 /ph



6/21

#4 100 meg 9.4 /ph

Mixing nozzles downstream spool in

1st Comp. All 4 Nos

2nd Comp. All 4 Nos3rd Comp. All 4 Nos.

4th Compt. All 4 Nos. renewed.

PA drain pipes --- 1st Compt. All 4 nos Renewed

2nd Compt. All 4 nos Renewed

3rd Compt. All 4 nos Renewed

4th Compt. All 4 nos Renewed

Cross ------ 1st Compt. 3 Renewed

2nd Compt. 2 Renewed

3rd Compt. 1 & 2 Renewed

4th Compt. All cross found in good condition

Coal nozzle cap 1st Compt. 2 Renewed

2nd Comp. All caps found in good condition

3rd Comp - 2,3 & 4 Renewed

4th Compt. 2 & 3 Renewed

PA fan #1 fan bearings inspected found normal grease renewed. PA fan

#1 Discharge damper inspected found gasket and bearing damaged. It was

renewed and then trial run taken found normal.

PA fan #1 Motor winding and cable Phase to earth & phase to phase I.R Value :

200m, Phase to phase; W.R Value : 0.5 /ph. Bearing both ends lubrication,

feeder side checking work done.

PA fan #2 Discharge damper inspected found gasket and bearing damaged. It was

renewed and then trial run taken found normal PA fan #2 Motor winding and cable Phase to earth & phase to phase I.R Value :


feeder Power and control cable terminal inspection work done.

FD fan motor side power cable melted, so cable-1&2 new glanded, lugged and

terminated, DE and NDE bearing and grease renewed, megger value was checked-

750 meg /phase.

FD Fan, lignite, Coal, Lime stone VFD panel cleaning and Power and control cable

terminal inspection work done.



7/21

ID Fan motor DE and NDE bearing and grease renewed, megger value was

checked-750 meg /phase, VFD panel cleaning and Power and control cable

terminal inspection work done.

ID fan DE and NDE Bearings and Plummer block renewed, alignment work wasdone.

Furnace, PSH and RSH were cleaned and all air nozzles air flushed.

BFW Pump #2 DE & NDE side bearing housing, bearing and stuffing box renewed.

All air boxes cleaned and boxed up.

Boiler drum was opened and inspected, found normal and boxed up.

BFW Pump both suction strainers cleaned and fixed back.

Deaerator was opened inspected, found normal and boxed up.

Economiser all inspection doors opened and inspected found normal then tube

surfaces cleaned with compressed air, boxed up and then taken on line.

Both Drum safety valves, HP Heater safety valve, LP Heater safety valve and Line

safety valve were serviced. Then, safety valve floating done the setting detail is

enclosed in Page No : 13

Oxygen analyzer calibrated.

BFW pump-1&2 Motor Megger value checked found to be R, Y&B Infinity, DE

and NDE bearing and grease renewed, air tubes cleaned.

TPP Auxiliary transformer #1 Break Down value (BDV) was checked.45KV-30SEC;

55KV-1min; 60KV-2min. Primary winding IR Value 1000 meg , Secondary

winding - 1000 meg . Bushing, cable & Bus inspection, breather silica gel reneweddone.

Auxiliary transformer #2 Break Down value (BDV) was checked.40KV-1 min;

50KV-1min; 60KV-10sec. Primary winding IR Value 1000 meg , Secondary

winding - 1000 meg . Bushing, cable & Bus inspection, breather silica gel renewed

done.

DG auxiliary transformer Break Down value (BDV) was checked - 40KV-1 min;

50KV-1min; 60KV-1min.



8/21

ACTIVITIES ON ASH HANDLING SYSTEM

ESP field I & II was cleaned by Compressed air wash.

Sys-110 hopper was observed with full level of ash, drained and all system hoppers

cleaned.

Ash collected at APH tube sheets on both passes was cleaned.

ESPI field collecting 1st 3rd and 6th hammer found missing was replaced and Shaft

support bearing housing worn out-2 nos and renewed.

ESP Transformer #1 Break Down value (BDV) was checked - 40KV-1 min; 50KV-

1min; 60KV-10sec. Primary winding IR Value 500 meg , Secondary winding -500 meg . Bushing, cable & Bus inspection, breather silica gel renewed done.

ESP Transformer #2 Break Down value (BDV) was checked - 45KV-1 min; 50KV-

45sec; 60KV-15sec. Primary winding IR Value 500 meg , Secondary winding -

500 meg . Bushing, cable & Bus inspection, breather silica gel renewed done.

All rapping motors general maintenance done.

ESP-1&2 all insulators, field collecting plate and emitting rods inspection work

done.

AHP MCC panel, ESP MCC panel, ESP controls panel-1&2, P&V Blower MCC panel,

ACDB Panel, APDB MCC panel bus, cable chamber and all feeders maintenance

work done.

Battery charger panel-1&2, DCDB panel bus, cable chamber and all feeders

maintenance work done.

Ash hopper all level probes serviced and fixed back.

AHP all system BFVs & MCVs serviced and fixed back.

All oil AFRL were renewed.



9/21

ACTIVITIES ON COAL HANDLING PLANT

CHP MCC panel bus, cable chamber and all feeders maintenance work done.

Crusher motor DE and NDE bearing and grease renewed, megger value was

checked-150 meg /phase.

All hammers of coal crusher turn it.

Dust extraction bag filter inspection and cleaning work was done.

Dust extraction bag filter hopper bottom side modification work was done.

In dust separator line back filter area all SOVs were calibrated and found ok.

ACTIVITIES ON TURBINE AUXILIARIES

Turbine lube oil cooler was opened cleaned and taken on line after leak check.

Lube oil filter elements 6 Nos renewed for A Filter and for B all elements

cleaned and fixed back.

All CEP, MCW Pumps and ACW Pumps suction strainers cleaned and fixed back.

Alternator cooler tubes were checked found OK. Third alternator cooler was

cleaned with rod with brush and water jet with service water.

In Main condenser front and rear inspection doors opened and found the tube

sheet and tubes are free from deposits, fouling etc. general checked up done and

boxed up.

I&C Air Compressor-1&2 winding and cable Phase to earth & phase to phase I.R

Value : 100m, Phase to phase; W.R Value : 0.6 /ph. Bearing both ends

lubrication, feeder side Power contactor renewed, power & control cable terminal

inspection work done

Turbine MCC panel bus, cable chamber and all feeders maintenance work done.

CEP-1&2, CWP-1,2&3 winding and cable Phase to earth & phase to phase I.R Value :


feeder side power & control cable terminal inspection work done



10/21

CT Fan-1&2, ACWP-1&2, AOP, EOP, Turning gear, VEM-1&2 Motor side

maintenance work done.

After the turbine O/H HP Governing actuator operation was checked andcalibrated found normal.

Turbine ESV limit switches & turning gear engage limit switch serviced and fixed

back.

ACTIVITIES ON RO / DM PLANT & COOLING TOWER

MGF open backwash was done after soaking the media in Hcl for 30 minutes.

ACF open backwash carried out.

Service water tank, RO-I & II rejects sumps were cleaned.

DM Plant MCC panel, Fire & Raw water MCC panel & 2 nd RO plant MCC panel bus,

cable chamber and all feeders maintenance work done.

DM Plant HPP-1&2 Power contactor renewed work done.

CT Fan-1, ACWP-1 Power contactor renewed work done.

Cooling water sump was cleaned and Fills were cleaned with water jet up to the

reachable distance.



11/21

OTHER ACTIVITIES

The 12.5 MW Captive power plant along with its auxiliary systems were taken

shutdown on 05-07-2010 at 00.10 Hrs for taking annual maintenance. Apart from thejobs done by us, we have also coordinated for the works done by other agencies

during the shutdown like :

1. Turbine Major overhauling was carried out by M/s S V Turbo Engg. Works.

2. Cooling tower fan # 1 gear box and base frame renewed by M/s Dynamic

Engineering.

3. Bucket elevator repairing work was carried out by M/s DRK contractors.

4. PCC-1&2, all MCCs, BFWP-1&2, GCP, GRP and TG incomer relays testing was done

by M/s Elsy Tech.

5. All LT ACBs serviced by M/s L&T.

6. TPP to DG-2 DSLC panel commissioning work U/P by M/s Wartsilla.

7. TPP Main/Stand by battery bank load tested by M/s HBL.

During the course of 18 days long shut down activities stringent safety practices

were followed and the shutdown is completed safely with zero incidents reported.

On completion of all planned shut down activities, DP test was done and TPP was

started and synchronized on 23.07.2010 at 20.28 Hrs .



12/21

SAFETY VALVE SETTINGS REPORT

Drum safety valve 2 Nos. and super heater safety valves were serviced assembled

back to original settings.

Drum LHS / RHS Safety Valve Model / size : 2 J2 4 HCI

Super heater Safety Valve Model / size : 1.5 H2 3 HCI

During the safety valve floating / setting on 22.07.2010 the following settings were

done:

Name of the

safety Valve

Set

pressure

Actual lift

Pressure

Resetting

PressureBlow down

Drum LHS 78 kg/cm2 77.4 kg/cm274.5

kg/cm23.75%

Drum RHS 77 kg/cm276.5

kg/cm274.4 kg/cm2 2.75%

Super heater 69 kg/cm2 69.7 kg/cm2 67.7 kg/cm2 2.86%

At normal operation above valve performance result found satisfactory.



13/21

TURBINE DISPLACEMENT / SPEED / VIBRATION PROBES INSPECTION &

MEASUREMENT REPORT

TAG NO : ZE 3400-A

SERVICE : Turbine Axial (thrust) displacementMAKE : BENTLY NEVADA

PROBE CABLE LENGTH : 5 METER

PROXIMITOR MODEL: 3300 XL 5/8 MM

P/N : 330180-50-00

OUTPUT : 7.87 V/mm (200 mV / mil)

GAP

VOLT

AGE

BENTLY

NEVEDA

PANELDISPLAY

DCS

MONITOR

DISPLAY

SENSO

R

ST

AT

US

PROXIMITOR

STATUS

06.07.1

0

BEFORE

DISMANTLIN

G- 11.85V

1.930 m

/pp0.07 mm OK OK

21.07.1

0

AFTER

MOUNTING -10.0V0.0 m/p

p0.0mm OK OK

TAG NO : ZE 3400-B

SERVICE : Turbine Axial (thrust) displacement

MAKE : BENTLY NEVADA



P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLYNEVEDA

PANEL

DISPLAY

DCSMONITO

R

DISPLAY

SENSOR

STA

TUS

PROXIMITO

R STATUS

06.07.1

0

BEFORE

DISMANTLI

NG- 11.39V 1.549 m/pp 0.05mm

OK.OK

21.07.1

0

AFTER

MOUNTING -10.0V 0.0 m/pp 0.0mmOK

OK



14/21

TAG NO : KQE 3400

SERVICE : Turbine speed measurementMAKE : BENTLY NEVADA



P/N : 330180-50-00


GAP

VOLT

AGE

BENTLY

NEVEDA

PANEL

DISPLAY

DCS

MONITOR

DISPLAY

SENSOR

STA

TUS

PROXIMIT

OR

STATUS

06.07.10BEFORE

DISMANTLING - 9.7V OK OK

06.07.10AFTER

MOUNTING -10.0V OK OK

TAG NO : VE 3400-A

SERVICE : Turbine front shaft vibration

MAKE : BENTLY NEVADAPROBE CABLE LENGTH : 5 METER


P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE

DISMANTLING - 10.1 V0.920

m/pp

0.49

micronOK OK

21.07.10AFTER

MOUNTING -10.00 V0.872

m/pp

0.49

micronOK OK



15/21

TAG NO : VE 3400-B

SERVICE : Turbine front shaft vibration




P/N : 330180-50-00OUTPUT : 7.87 V/mm (200 mV / mil)

GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.49

micron OK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

TAG NO : VE 3401-A

SERVICE : Turbine rear shaft vibration


PROBE CABLE LENGTH : 5 METERPROXIMITOR MODEL: 3300 XL 5/8 MM

P/N : 330180-50-00


GAP

VOLT

AGE

BENTLY

NEVEDA

PANEL

DISPLAY

DCS

MONITOR

DISPLAY

SENSO

R

ST

AT

US

PROXIMIT

OR STATUS

06.07.10

BEFORE

DISMANTLIN

G- 9.9 V

0.630

m/pp

0.49

micronOK OK

21.07.10AFTER


m/pp

0.49

micronOK OK



16/21

TAG NO : VE 3401-B

SERVICE : Turbine rear shaft vibration





GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLAY

DCS

MONITOR

DISPLAY

SENSOR

STA

TUS

PROXIMITOR

STATUS

06.07.1

0

BEFORE


m/pp

0.49

micron OK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

TAG NO : VE 3402-A

SERVICE : Gear box high speed shaft vibration



PROXIMITOR MODEL: 3300 XL 5/8 MMP/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10 BEFOREDISMANTLING - 9.16V

0.530

m/pp

0.49

micronOK OK

21.07.10AFTER


m/pp

0.49

micronOK OK



17/21

TAG NO : VE 3402-B

SERVICE : Gear box high speed shaft vibration





GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.49

micron OK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

TAG NO : VE 3403-A

SERVICE : Gear box low speed shaft vibration


PROBE CABLE LENGTH : 5 METERPROXIMITOR MODEL: 3300 XL 5/8 MM

P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE

DISMANTLING - 9.90.633

m/pp

0.49

micronOK OK

21.07.10AFTER


m/pp

0.49

micronOK OK



18/21

TAG NO : VE 3403-B

SERVICE : Gear box low speed shaft vibrationMAKE : BENTLY NEVADA



P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.49

micronOK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

TAG NO : VE 3404-A

SERVICE : Generator front shaft vibration




P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSORST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.53

micronOK OK

21.07.10AFTER


m/pp

0.49

micron

OK OK



19/21



20/21

TAG NO : VE 3404-B

SERVICE : Generator front shaft vibration





GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.59

micron OK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

TAG NO : VE 3405-A

SERVICE : Generator rear shaft vibration

MAKE : BENTLY NEVADAPROBE CABLE LENGTH : 5 METER


P/N : 330180-50-00


GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.58

micronOK OK

21.07.10AFTER


m/pp

0.49

micronOK OK



21/21

TAG NO : VE 3405-B

SERVICE : Generator rear shaft vibration





GAP

VOL

TAG

E

BENTLY

NEVEDA

PANEL

DISPLA

Y

DCS

MONITOR

DISPLAY

SENSOR

ST

AT

US

PROXIMITOR

STATUS

06.07.10BEFORE


m/pp

0.49

micron OK OK

21.07.10AFTER


m/pp

0.49

micronOK OK

Documents

Shutdown Report July 10