TRIPPING EVENT ANALYSIS REPORT UNITNO :4 | TPS: Bhusawal TPS Unit Capacity: 500 MW a 7 i synchi— pee eae a Sinton Coa | Time: 09:21Hrs, | Date: 08/01/2017 Nes ot cave foes st 2, Last COH/ AOH Date: 3. Operating conditions at the time of Event: Tripping Event. ‘Load MW: Coal Cycles in service: Support: 251MW CDE NIL 4 Nature of Event: Due to tube leakage suspected in water wall of the boiler. The TG Set hand tripped. 43. Name of First Up, Main Protections & protection on which GCB tripped: Unit withdrawn for BTL. First Up + Boiler protection. Generator Tripped on: Reverse power protection, (Mechanical). Turbine Tripped on: Turbine tripped. Boiler Tripped on____: Turbine trip to boiler tripped. 6 A) Observations: Tube leakage in water wall of the boiler was suspected. As there was steam water leakage noise at 39M level since 07.01.2017, the drum level was maintaining at negative and difference in steam & feed water flow increased up to 200 TPH. B) Remedial Action / work done: 1) RHS water wall tube no.61 was having soot blower steam erosion at 43 mir elevation. 2) RHS water wall tube no.56, 57,58,59,68 were eroded & Total no of joints is 14. 3) RHS water wall tube n0.60,61 were damaged due to overheating at 55 & 58 mtr elevation & total no of joints is 10 7. Root Cause Analysis: - 1) RHS water wall tube no.61 was having leakage soot blower steam erosion near SB no. - 30 at 43 mtr elevation. 2) RHS water wall tube no.60,61 was having fish mouth opening due to overheating at 55 mtr & $8 mtr elevation respectively. 8, Preventive action suggested (Short Term): Joint inspection & trial BM, EM & Operation staff of WSB once in every fortnight for correct operation of WSB. 9. Preventive action suggested (Long Term): In long shutdown of unit, soot blower erosion checking will be carried ‘out & eroded tubes will be replaced. 10. ir event occurred last time: | Unit No. Time: Hrs. Date: 10A. Implementation Status of Long Term / Short Term measures stated at No. 9: 11. Boiler lighted up: Time: 16:42 Hrs. Date: 10/01/2017 2. T-G Set Synchronized: Time : 03:09 Hrs. Date: 11/01/2017 13. Remark: 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: 5. Training of Staff: ‘6. Whether rem: action is completed satisfactory & point is elosed : C.E./ Dy. CE (Works) *HO Code will be given by Works Section.Work carried out in unit 4 BTPS shutdown by TM500 from 8/1/17 to 10/1/17 1) HPH SA and 58 drip to deareator NRV bonet leakage attending. 2) HPH SA water box drain and 6A shell drain replacement. 3) Drain near DRV15 replacement 4) MS Line pressure sensing line isolation valve replacement 5) FOV 11 gland replacement 6) MDBFP AC DE side bearing oil leakage 7) LPBP breather filter checking and cleaning 8) TDBFP 4A and 4B rv coupling setting 9) TOBFP 48 BP suction pipe flange leakage 10) HPH 6A ext line drain vaive gland bolt replacement 11) HPH SA ext line isolation valve gland bolt replacement 12) TDBFP 48 main pump MS cooling line vent valve replacement Add. sikeatie ingineer TM 2X 500 MW, MSPGCL, BTPS, Deopnagar Executlve Engineer ‘TM 2x500 MW MSPGCL, BTPS, Deepnagar4 Work to be carried out by EMT-500 during U#4 shutdown, From 08.01.17 to 11.01.17:- 1) GT-4A HV winding temp. not showing correctly at PCR, defect attended. 3) HRHV-109, SMV-1, SMV-7, S0-35, FDV-13, FDV-7, FDV-8, TDBFP-44 MTW70AA252, $-174, CHDV-6 MOV defect attended. Trial taken, found OK. 3) ID Fan-4A, 4B Ch-l & Ch-2. one by one Zener diode installation, 4) BCW-4A, Coal Mill-4A, its RCF & LOP one by P/M 5) DC scanner fan, HP seal water pump-1, LP seal water pump-1 & 2, Fludizing Blower PIM carried out. 6) BASP A6 breaker alignment done 7) ESP field 2B21 & 7C11 attended after B/M work completion. Focbtore Adl. Executive €1 ngineer Al | ale Elect. Maint.,500 MW. Exeeutive En ji E.M.&T., xE00MW.‘TUBE LEAKAGE REPORT 1 REPORT NO.: 16-17/4 UNIT: 4 DATE OF WITHDRAWAL: 08 /01/2017, 09:21 hrs .* OBSERVATIONS:- Noor |NOOF ZONE LOCATION | PRIMARY FAILURE | SECONDARY FAILURE ag JOINTS | Rays RHS WW__| 1) RHS Water |-1) RHS Water Wall | 1) RHS water wall tube no. 56, : Wall tube | tube no. 61 was having | 57,58,59,60 were eroded. n0.61 at 43 | soot blower steam meter erosion at 43 meter 4 4 elevation. _| elevation. b) RHS Water 2) RHS water wall tube no, 60& Wall tube no. 61 were damaged due to 60 at 55 meter overheating at 55 meter & 58 & RHS Water meter elevation 10 10 Wall tube no. 61 at 58 meter elevation. TOTAL| 24 [24 ANALYSIS: RCE aA TERIA Rifled Tube SA210 Gr.C 6 51. X 5.6 mm. DATE OF INSTALLATION OF TUBE Since commissioning. 1) RHS Water Wall tube no. 61 was having soot blower steam| VISUAL EXAMINATION erosion at 43 meter Elevation. 1) RHS water wall tube no 61 having erosion opening @ 10 PHYSICAL EXAMINATION mm near soot blower no, 30 at 43 meter elevation, L FINDINGS: 1) RHS water wall tube no 61 having leakage due to soot blower steam erosion near SB no -30 at 43 meter elevation, 2) RHS water wall tube no 60 & 61 having fish mouth openings due to overheating at 58 meter & 55 meter elevation respectively. Short Term: Joint inspection & trial by BM, EM & Operation staff of WSB once in every fortnight for correct operation of WSB. Long Term: In long shutdown of unit, soot blower erosion checking will be carried out & eroded tubes will be replaced. wr xe E.E, (BM-S00MW)HH LING PI Work carried out during U4 shutdown 08/01/2017 > BOTTOM ASH & FLY ASH EVACUATION SYSTEM * Bottom ash hopper- cleaning work done * Seal trough cleaning work done. © Clinker grinder 3 replaced. * B/A hopper flushing line choke up removed & modification done. * ALA. B, C, D buffer hopper internal inspection done. * Fluidizing pad leakages attended. * Seal trough overflow line modified. * C&D pass conveying line bends replaced. Executive Engineer AHP Maintenance-500 MW. B.T.P.S. DeepnagarStart Up Analysis during the month UNIT NO.IV Date & Time of trip Turbine Casing Temp at Start up ( Deg c) Tyre of Start UP ( Cold / Warm / Hot) BLU ON PRDS Charging FO Changeover Fire Killing Header Blow Down Completion Boiler Relight UP Vacuum Pulling R “ing started Synchronization Oil Support withdrawn at Oil Cons (LDO / FO) till Oil withdrawn KL. Full Load/Max Load achieved at (Load & Time) Date & Time Time Benchmark 08/01/2017 09:21 hrs taken from BLU 08/01/2017 09:21 Hrs 323/293°C Warm Start Up 40.01.17 at 16:42 hrs 18:50 hrs CD Elevation:21:00hrs AB Elevation:22:45 hrs 23:21hrs 22:30 hrs 11.01.17 at01:03 Hrs 11.01.17 at 03:09 Hrs 41.01.17 at 08:30 Hrs LDO: 24 KL HFO: 90 KL 492 MW at 12:00Hrs Problems Faced During Start UP: While change over LDO to HFO for AB elevation oil guns. The guns did not proved early. After so many times try, took about 30 min time to prove all light up process at every command to guns tembha utilized to ignite. The generator breaker was not getting closed while synchronizing problem occurred in switch yard breaker control circuit. 1hrs 45 min i.e. 01:20hrs to 03:05 hrs time taken to investigate and attend the problem.