aii isl A init nn tn UNIT NO : 4 | TPS: Bhusawal TPS Unit Capacity: 500 MW. 17H Code: [Station COU: Tine: 1530 Hr, | Date: 157082015 | Nod fom law ayn :7 2. Last COH / AOH Date: 3. Operating conditions at the time of Event : Load MW: Coal Cyeles in service: Oil Support: 132MW ‘A,B (with coal flow zero) AB Elevation ~3 Guns (F.O) for 5 minutes. “4 Nature of Event: T.A Set withdrawal due to Boiler Tube Leakage @ 40 mtr. level ‘5. Name of First Up, Main Protections & protection on which GCB tripped: First Up: “Boiler emergency tripped.” Generator Tripped on: “ Reverse power protection(mech)” Turbine Tripped on: “MFT operated” Boiler Tripped on: “Hand tripped” 6A) Observations: “Detailed sheet is attached” 6B) Remedial Action /work done: Leakage attended by ™ | defective tubes replaced. grooving and HP welding with radiography and 7, Root Cause Analysis: “Detailed sheet is attached ” 8. Preventive action suggested (Short Term): 9. Preventive action suggested (Long Term): “Detailed sheet is attached ” 10, Similar event occurred last time: | Unit No. Time: Hrs. Date: TOA. Implementation Status of Long Term / Short Term measures stated at Sr. No. 9: II. Boiler lighted up: Time : 17:25 Hrs = 1770872015 12. T-G Set Synchronized: ‘Time : 01:53 Hrs IS REMATK Bw, eube emotion) Patten in Sot blew ona se \be ebserr~edl 17 ADH: Foalwe. Seen 4s Bb corm reo) Ort by cPRE and arabyrts “to be alt BTPS, Deepnagar 14, Recommendations of Works Section: 1, Procurement/Replacement Plan: 2. Operational Error: 3. Delay in Maintenance: 4, Delay in bringing back the Unit: . Training of Staff: 6. Whether remedial acti is completed satisfactory & point is closed : E./ Dy. CE (Works) *HO Code will be given by Works Section.‘TUBE LEAKAGE REPORT 1 REPORT NO.: 15-16/3 UNIT: 4 DATE OF WITHDRAWAL: 13/08/2015, 19:30 hrs ae OBSERVATIONS:- | ee ee loos malt an RENO DHE | PRIMARY Noor |? ZONE — | LOCATION | FAIURE SECONDARY FAILURE jot |X. | RHS waterwall | SB No. 32 RHS Secondary erosion to SB No. 38/38 at 42 mtr, level | Tube no. 3 thin lip | RHS tubes 1.2.4.5,6.7,8 & ‘opening due to soot | SB No.32 LHS tubes 1,2.4.5.6.7, blower erosion at 42) 8.9 mtr, level [RHS waterwall | Tube no. 73 Secondary erosion to tube no-72 44 | at 24 mur. level | pinhole at 24 mtr | at 24 mur. level. level . ANALYSIS: Mines ee MATERIAL | SA210 GrC 51 X 5.6 mm Rifled tube DATE OF INSTALLATION OF TUBE Since com ~—__| 1) Thin Tip opening of SB No.32 RHS tube no.3 of RHS water wall at 42 mtr, VISUAL EXAMINATION 2) Pin hole opening observed on tube no. 73 of RHS waterwall at 41 mtr, 1) Thin lip opening observed @ 12mm width X 90mm length near SB No.32 RHS water wall tube no.3 at 42 mir. level PHYSICAL EXAMINATION 2) Pin hole opening observed @ 2mmX 4mm of RHS water wall tube no, 73 at 24 mtr. FINDINGS: |. SB No.32 RHS water wall tube no.3 failure due to soot blower erosion at 42 mtr. level. 2. Pin hole opening of RHS water wall tube no.73 at 24 mit level. WORK CARRIED OUT 1, Leakage attended by “V" grooving and HP welding with radiography and defective tubes replaced.‘TUBE LEAKAGE REPORT 2 RECOMMENDATIONS: Long Term: 1. In long shut down of unit, Soot blower erosion checking will be taken and eroded tubes, will be replaced. = BENCH SRNO ACTIVITY TIME Potion | MARKING |e 2 a as z RIOD |__ PERIOD 1 | UNIT WITHDRAWN 13-08-2015, 19:30 hrs_| 00:00 hrs 2 | TUBE LEAKAGE DETECTED _| 14-08-2015, 14:00 hrs_| 18:30 hrs DATE & TIME OF 3. | HYDRAULIC TEST AT 170 16-08-2015, 03:00 hrs | $5:30 hrs | eS {ikprerm beers : - 4 | CLEARANCE FOR LIGHT UP | 16-08-2015, 15:45 hrs | 68:15 hrs i Ss 16-08-2015, 17:25 hrs_| 69:55 hrs _ SYNCHRONIZED AT 17-08-2015, O1:53hrs | 78:26 hrs Note: 1) Due to different locations of leakages, sky climber erection at different places required. 2) During attending tube leakage due to buck stay obstruction below SB No.32 eroded tube length increased & also fin welding time increased. ma GEE IVE ENGINEER E BM, 2XS00MW BTPSSTART UP ANALYSIS DURING THE MONTH > TIME TAKEN UNITNG ? = a A FROM BLU BENCHMARK DATE & TIME OF TRIP ronpivreasive TEMP Ar MEE 306/279 START UP( DECC) (POP/BOTPOM) TYPE OF STARTUP vp UU (COLD) WARM SHOT) co d BLU ON \7:25 PROS CHARGING 216 - FO CHANGEOVER 14) So 7 PURE KILLING ea HEADER BLOW DOWN 22-67 COMPLETION BOILER RELIGHT UP ee VACULM PULLING 22:50 foLane stawreD poe (rial i SY NCHRONISATION { 5 Bue osuerorrwrrmmaws 05°80 Ws OIL CONS (LDOIFO) HLL OL, WEPHDR AWN FULL LOADAIAN LOAD ACIIIEVED AT (LOAD & TIME) PROBLEMS PACED DURING ( STARTUP.