TSPL UNIT#2 OVERHAULING REPORT

DATE Man
S.N. Major planned job Observation
START ENDING power
1.00 Turbine and Generator
proper

MOT internal inspection & Man hole opened & bottom settled dirty oil was removed with cloth and thoroughly cleaned with
1.01
cleaning wheat flour. After cleaning, inspection was done by TSPL. man holes closed.

MSP, TOP, DC LOP All 3 pumps decoupled and motors were taken out for testing . after receiving motors alignment
1.02 inspection and checking, was checked & coupled. All 3 pumps strainers were physically inspected & found OK. No loose
BOP, EXHUST FAN fittings found in pipe lines.

DATE Man
S.N. Major planned job Observation
START ENDING power

2.00 Condensate System

Outlet line 2 manholes were opened for OLTC screen inspection .Screen was cleaned & inspected.
OLTC Screen checking
2.01 Oil was poured in links & manholes were closed
for no ball passing

All 3 pumps were decoupled. Pump (B) motor was tested. Alignment of all # pumps were choked &
Vacuum Pump alignment
2.02 corrected. Couplings were inspected & found OK. All the 3 pumps were coupled.
and inspection

CEP suction strainer

2.03 Strainers A& B were opened, cleaned & inspected. Strainers were assembled back.
cleaning

Both CEP bearing housing CEP(B) bearing housing leakage was attended by replacing scraper ring. Pump A scraper ring yet to
2.04
leak to be attended be replaced.

Hotwell and condenser Hotwell both manholes were opened. hotwell thoroughly cleaned &inspected Man hole doors were
2.05
inspection and cleaning closed.
CST manhole was opened, floating ball was taken out & cleaned resin was taken out & cleaned
CST tank inspection and
2.06 resin was collected out. tank was thoroughly cleaned , coating was inspected and formed ok.
cleaning
Floating ball was placed back in position and man hole was boxed up.
 Valve stroke checking,
2.07 All valves stroke was checked, Greasing was done and calibrated. Details enclosed.
greasing, calibration

Overhead CCCW make up

overhead CCCW make up tank man holes was opened, cleaned and inspected. Finally manhole
2.08 tank inspection and
closed.
cleaning

2.9 CEP alignment inspection CEP (2B) pump decoupled, alignment checked corrected and coupled.

Starting Ending Man

3.00 Feed Heating System Observation
date date power

Suction Valve was dismantled, gland found OK. blue matching of valve seat and cone was done &
inspected by customer. Bonnet gasket was replaced and valve was assembled.
TDBFP Booster pump
3.01
suction valve passing

Dearatore inspection Deareator both side man holes were opened & entire Deareator was cleaned thoroughly & then man hole
3.02
and cleaning was closed.

Valve stroke checking,

3.03 All valves in feed heating system stroke checking greasing and calibration was done.
greasing, caliberation

Booster pump strainer Strainer were taken out. cleaned with air & reassembled back in position. Strainer were found in good
3.04
cleaning condition.

MDBFP Booster pump Both the bearing top cover opened & bearings were inspected & found ok.NDE side oil ring was found
3.05
alignment checking damaged &the same were replaced.
 Pump was decoupled and pump float was checked. Both side journal bearing & thrust bearing was opened
MDBFP alignment
3.06 & bearing clearance were recorded. DPT of bearing was done and found OK. Bearing clearances and
checking
alignment values enclosed separately.

MDBFP strainer
3.07 MDBFP suction strainers was taken out cleaned and assembled back in position. Strainer was found OK.
cleaning

HP Heaters -1,2,3 man hole doors were opened HP heater 1, 2 studs 4 nos were damaged during opening of
HPH internal
3.08 manholes & the same were replaced. visual inspection was done, some metal pieces and nuts were found
inspection
inside the heates 1&2. The same was taken out. HP heaters 1,2,3 man hole doors were closed.

4.00 Preventive Starting Ending Man

Observation
Maintenance date date power

Stator cooling water

stator water cooling system tank manhole opened. no foreign particles found. after cleaning it was
system tank cleaning,
inspected fine filter was taken out, cleaned reassembled top plates cleaned and found OK. Strainer was
strainer cleaning,
4.01 opened and cleaned.stator water cooling pump both were decoupled after motor testing alignment checked
mixed bed tank
and coupled. Filters were found opened mesh was found with dust particles, it was cleaned and
inspection,filter
reassembled stator water cooler flange opened gasket replace and assembled.
inspection

Tank manhole opened & sediments layer was found. The same was removed with wheat powder. Strainer
Seal oil system skid
was opened and found dirty, after cleaning strainer was assembled back. Float ball link was inspectede &
4.02 fliter cleaning and
adjusted to maintain oiul level. DC seal oil pump was decoupled for inspection of motor, After alignment
tank cleaning
Checked, it was coupled. Seal oil Vacuum pump was taken out and waiting for spare pump.

Jacking oil filters

4.03 Jacking oil filters were taken out, cleaned and assembled back.
cleaning

All lube oil/hydraulic

4.04 oil coolers internal Third party has done
chemical cleaning

Lub oil and EH oil

4.05 lines thickness Checked found suitable.
checking

Lub oil line welded

4.06 Checked and found OK.
joints DPT
 Top pumps All three nos. were decoupled and motors were and taken out. After electrical testing of motors.
4.07 MOT all pump PM Top pumps alignment was checked and assembled. All strainers of these pumps were checked and found
OK.

TD BFP oil tanks TDBFP A & B oil tank manholes were opened and some sediments deposits were found & same was
4.08 internal cleaning and cleaned and inspection done buy coustomer. oil tanks were cleaned with wheat powder. Manhioles of
inspection TDBFP tanks were closed.

Replacement of
4.09 oilfilters(lube oil, EH After oil flushing of filters will be replaced.
oil)

overhauling of DP
4.10 valves setting checked and found ok.
valves
DEH skid filter &
4.11 Filters cleaning done and one damaged filter replaced.
tank cleaning
HP by pass skid filter
4.12 oil drained and skid cleaning and inspection done . oil top up done.
& tank cleaning
Startin
Ending Man
5.00 HV&AC g Observation
date power
date

chiller condenser
5.02 chiller-A, B & C inspection & condenser chemical cleaning done.
chemical cleaning

AHU air filter

5.03 AHU air filter machine –A, B, C & D all filters cleaned & inspection done.
cleaning

6.00 Dosing & SWAS Starting Ending Man Observation

system date date power
permit not issued due to isolation.
Tank internal
6.01 inspection
permit not issued due to isolation.
6.02 Attending of any
defects.
 Star
Ending Man
7.00 Cooling water system ting Observation
date power
date

CW brush cleaning not in our scope

7.01
system not working

Cooling Tower inspection

7.02 not in our scope
and repair work if any

7.03 CT basin cleaning not in our scope

OCCW pump A& B were decoupled, top casing were opened, rotor were taken out and sleeves were
found damaged on both the rotors. casing & rotor were cleaned, coating was done inside of casing. Pump
OCCW pump
7.04 –A NDE side bearing was replaced as there was some sound in the ball bearing. 4 shaft sleeves were
overhauling
replaced with new sleeves. Gland rope was replaced for the pumps both the pumps were assembled in
position. Pump-A alignment checked and coupled. Pump-B alignment kept pending for motor

7.05 OCCW strainer cleaning OCCW strainer doors were opened & cleaned with water jet & air.

CW hydraulic skid skid oil drained, man hole opened, internal cleaning & inspection done, For external purification
7.06
checking modification done and oil top up done.

Starting Ending Man

8.00 Auxiliary piping Observation
date date power

Replacement of low
8.01 /HIGH pressure Annexure Enclosed.
passing drain valve
 Gland packing repl.
8.02
of MOVs

Valve stroke
8.03 checking, gerasing,
calibration

FCNRV stroke
8.04 Stroke checking done by C&I person
checking

HP Bypass spray
8.05 Cancelled by customer.
nozzle inspection

MSL, CRH, HRH,

HP BP, LP BP, FW Hangers supports at 0, 6.9 & 13 meters were inspected & settings are within the permissible limits.
8.06
line hanger (details enclosed)
inspection

Starting Ending Man

9.00 Defects Observation
date date power

Work done before shut down.

H2 skid 1 outlet
9.01
valve jamming

Underperforming
9.02
cooler up gradation
 CCCW pump B
9.03 Pump decoupled after motor inspection alignment done & coupled.
alignment check

Insulation repair
9.04 MSSV insulation works completed.
jobs

Starting Ending Man

10.00 CPP Observation
date date power

Mixed bed internal Permit not yet given.

10.01
inspection

CPP resin trap

10.02 strainer
replacement

Starting Ending Man

11.00 Modification Observation
date date power

CPP unit vent to be

Work done before shut down.
11.01 brought down to
drain trench

HP LP bypass valve
Work done before shut down.
11.02 bonnet bolts
replacement

LP Bypass valve
11.03
A&B passing
 Vent line mod. to
11.04
avoid online leaks

Pressure vessel
12.01 Third party inspection
internal insp.
 Startin
Major planned Ending Man
SI.NO g Observation
jobs date power
date

Pedestal top covers of Bearing no.3,4,5,6,7,8 ,9 were Taken out. and interference and Stroke clearances
between bearing shell top half and bearing housing were checked with lead wire.
For all bearings 3,4,5,6,7,8,9.Bearing Top halves were opened and Top oil clearance and side oil clearances
were checked .by tightening the Bearing top and bottom halves .Both Top and bottom halves taken out and
Turbine & generator
inspected scoring marks were Observed on Bearings as well as Journals.
1.0 bearings inspection ,
Journals were polished and Bearings were scraped, DPT and UT tests were conducted for Bearings are
DPT, UT, TOC, seal.
found to be good, after assembly of all bearings oil Guards were assembled clearances 0f top and side oil
clearances were noted. Readings noted. enclosed. All the pedestal top covers were reassembled one by one.

Generator rotor
2.0 Not taken Up the Job.
threaded out.

MSV strainer MSV strainers top cover cap nuts were opened by induction heating.3 dowel pins were found in
3.0
inspection In strainer A, strainers cleaned with compressed air,and reassembled A&B .

LP-A bypass valve 1 assembly send to w/s. it was not secting properly. build up material & machined in the
w/s, graphite gasket replaced as the gasket were damaged.
LP by-pass valve A& LP-B by pass valve stem assemble replaced with new one as this not applicable to repair with W/S. LP
4.0
B passing bypass valves opened and inspected it was found that sealing surfaces were damaged.one of the valves seat
and cone was replaced , other one valve seat machined and refitted. Both the valves blue matching checked
between cone and seat, after inspection contact area found good both the valves were assembled.

Servicing of high
5.0
pressure drain valve
 TDBFP turbine
6.0
bearing inspection

7.0 BFP bearing 2A,2B Bearing cover removed , cleaning done, DPT carried out, no cracks found, reassembled.

BFP thrust bearing BFP thrust bearing dismantled, inspected, thrust pads cleaned DPT done. Found OK
8.0
inspection re-assembled

BFP axial shift

9.0 BFP 2A, 2B axial checked recorded - 0.48 t0 0.49 mm
checking

BFP alingment
10.0 BFP alignment checked.
checking

TDBFP alignment
TDBFP-2A . coupling dismantled, alignment checked reading found OK. alignment found OK
11.0 checking &
correction.

TDBFP-A lOP A
12.0 Pump dismantelled , blue matching done b/w motor and pump flang Over hauling done
pump overhauling.

TDBFP spring
13.0 Spring inspection done, spring height was recorded (95 mm). found OK.
inspection.

TDBFP rupture disc Rupture discs 2A &2B opened, inspected & found that disc gaskets in damaged condition. new gasket was
14.0
inspection replaced & reassembled the units.

CW pump thrust
15.0 Oil drained and inspection carried out, bearing found ok. oil refilled.
bearing inspecting
 LP blades- last stages A,B DPT done, no cracks found. bottom area cleaned & manhole closed.
16.0 LP blade DPT.

Turbine thrust pad

17.0 Work not attended.
inspection

LP turbine rupture
18.0 Turbine rupture disks 8 nos were inspected found ok. 1 disk was rectified and reassembled.
Disc inspection

Turning gear
19.0 Top cover plate opened, gears were visually inspected found in gppd condition cover plate reassembled.
inspection.