Shutdown Report July 10
Shutdown Report July 10
Shutdown Report July 10
JULY – 2010
SAMRUDDHI SITE
DESCRIPTION PAGE No
1) MAJOR EVENTS : 3
2) ACTIVITIES ON BOILER : 5
7) OTHER ACTIVITIES : 11
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.
All vertical and Horizontal PA line pipes renewed and extra gate additionally
added
BFW Pump #2 DE & NDE Bearing hosing, stuffing box and bearing renewed.
TPP & DG all HT panel and LT panel, GCP, GRP panel relays testing 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
TPP Main Battery Bank and Stand by Battery Bank Load test coordination and
checked found working normal.
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.
All Control valves & RPCs calibrated as well as stroke checked found normal.
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.
• Remaining fuels emptied from Lignite & Coal bunkers and all bunker lumps
removed.
• DCF #1, #2 & #4 renewed DE & NDE Shaft with sprockets and bearings.
• Boiler PA drain #1, #2, #3 and #4 compartment all pipe line renewed and
• Boiler PA horizontal #1, #2, #3 and #4 compartment all pipe line from Air
• 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
• All Drag Chain Feeder motors DE & NDE side bearing renewal and winding
• PA fan #1 Motor winding and cable Phase to earth & phase to phase I.R Value :
200mΩ, Phase to phase; W.R Value : 0.5 Ω/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 :
200mΩ, Phase to phase; W.R Value : 0.5 Ω/ph. Bearing both ends lubrication,
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 Ω/phase.
• FD Fan, lignite, Coal, Lime stone VFD panel cleaning and Power and control cable
terminal inspection work done.
• ID fan DE and NDE Bearings and Plummer block renewed, alignment work was
done.
• 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.
• Boiler drum was opened and 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
• DG auxiliary transformer Break Down value (BDV) was checked - 40KV-1 min;
50KV-1min; 60KV-1min.
• Sys-110 hopper was observed with full level of ash, drained and all system hoppers
cleaned.
• ESP–I 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 Ω, Secondary winding -
500 meg Ω. 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 Ω, Secondary winding -
500 meg Ω. Bushing, cable & Bus inspection, breather silica gel renewed 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.
• AHP all system BFVs & MCVs serviced and fixed back.
• 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 Ω/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 SOV’s were calibrated and found ok.
• 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 : 100mΩ, Phase to phase; W.R Value : 0.6 Ω/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 :
100mΩ, Phase to phase; W.R Value : 0.4 Ω/ph. Bearing both ends lubrication,
feeder side power & control cable terminal inspection work done
• After the turbine O/H HP Governing actuator operation was checked and
calibrated found normal.
• Turbine ESV limit switches & turning gear engage limit switch serviced and fixed
back.
• MGF open backwash was done after soaking the media in Hcl for 30 minutes.
• DM Plant MCC panel, Fire & Raw water MCC panel & 2 nd RO plant MCC panel bus,
• Cooling water sump was cleaned and Fills were cleaned with water jet up to the
reachable distance.
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 the
jobs 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.
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 .
Drum safety valve 2 Nos. and super heater safety valves were serviced assembled
back to original settings.
During the safety valve floating / setting on 22.07.2010 the following settings were
done:
76.5
Drum RHS 77 kg/cm2 74.4 kg/cm2 2.75%
kg/cm2
TAG NO : ZE – 3400-A
SERVICE : Turbine Axial (thrust) displacement
MAKE : 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)
SENSO
GAP BENTLY
DCS R
VOLT NEVEDA PROXIMITOR
MONITOR ST
AGE PANEL STATUS
DISPLAY AT
DISPLAY
US
BEFORE
06.07.1
DISMANTLIN 1.930µ m
0 - 11.85V 0.07 mm OK OK
G /pp
21.07.1 AFTER
0.0µ m/p
0 MOUNTING -10.0V 0.0mm OK OK
p
TAG NO : ZE – 3400-B
SERVICE : Turbine Axial (thrust) displacement
MAKE : 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
BENTLY DCS
VOL SENSOR
NEVEDA MONITO PROXIMITO
TAG STA
PANEL R R STATUS
E TUS
DISPLAY DISPLAY
BEFORE
06.07.1
DISMANTLI OK.
0 - 11.39V 1.549µ m/pp 0.05mm OK
NG
21.07.1 AFTER
OK
0 MOUNTING -10.0V 0.0µ m/pp 0.0mm OK
GAP BENTLY
DCS SENSOR PROXIMIT
VOLT NEVEDA
MONITOR STA OR
AGE PANEL
DISPLAY TUS STATUS
DISPLAY
BEFORE
06.07.10
DISMANTLING - 9.7V OK OK
AFTER
06.07.10
MOUNTING -10.0V OK OK
TAG NO : VE – 3400-A
SERVICE : Turbine front shaft vibration
MAKE : 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 BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.920 0.49
DISMANTLING - 10.1 V OK OK
µ m/pp micron
AFTER
21.07.10 0.872 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
GAP BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.920 0.49
DISMANTLING - 10.02 V OK OK
µ m/pp micron
AFTER
21.07.10 0.960 0.49
MOUNTING -10.0 V OK OK
µ m/pp micron
TAG NO : VE – 3401-A
SERVICE : Turbine rear shaft vibration
MAKE : 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)
SENSO
GAP BENTLY
DCS R
VOLT NEVEDA PROXIMIT
MONITOR ST
AGE PANEL OR STATUS
DISPLAY AT
DISPLAY
US
BEFORE
06.07.10 DISMANTLIN 0.630 0.49
- 9.9 V OK OK
G µ m/pp micron
AFTER
21.07.10 0.630 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
GAP
BENTLY
VOL DCS SENSOR
NEVEDA PROXIMITOR
TAG MONITOR STA
PANEL STATUS
E DISPLAY TUS
DISPLAY
06.07.1 BEFORE
0.561 0.49
0 DISMANTLING - 9.7 V OK OK
µ m/pp micron
AFTER
21.07.10 0.581 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
TAG NO : VE – 3402-A
SERVICE : Gear box high speed shaft vibration
MAKE : 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 BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.530 0.49
DISMANTLING - 9.16V OK OK
µ m/pp micron
AFTER
21.07.10 0.533 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
GAP BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.580 0.49
DISMANTLING - 9.26 V OK OK
µ m/pp micron
AFTER
21.07.10 0.533 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
TAG NO : VE – 3403-A
SERVICE : Gear box low speed shaft vibration
MAKE : 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 BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.633 0.49
DISMANTLING - 9.9 OK OK
µ m/pp micron
AFTER
21.07.10 0.533 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
GAP BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.588 0.49
DISMANTLING - 10.1 V OK OK
µ m/pp micron
AFTER
21.07.10 0.533 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
TAG NO : VE – 3404-A
SERVICE : Generator front shaft vibration
MAKE : 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 BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.681 0.53
DISMANTLING - 9.8 V OK OK
µ m/pp micron
AFTER
21.07.10 0.630 0.49
MOUNTING -10.01 V OK OK
µ m/pp micron
GAP BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.681 0.59
DISMANTLING - 9.6 V OK OK
µ m/pp micron
AFTER
21.07.10 0.581 0.49
MOUNTING -10.01 V OK OK
µ m/pp micron
TAG NO : VE – 3405-A
SERVICE : Generator rear shaft vibration
MAKE : 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 BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.630 0.58
DISMANTLING - 9.6 V OK OK
µ m/pp micron
AFTER
21.07.10 0.632 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron
GAP BENTLY
SENSOR
VOL NEVEDA DCS
ST PROXIMITOR
TAG PANEL MONITOR
AT STATUS
E DISPLA DISPLAY
US
Y
BEFORE
06.07.10 0.680 0.49
DISMANTLING - 9.4 V OK OK
µ m/pp micron
AFTER
21.07.10 0.581 0.49
MOUNTING -10.00 V OK OK
µ m/pp micron