NTECL VALLUR

Unit-2 Overhaul Recommissioning Report (2015)

UNIT - II

OVERHAUL
&
RECOMMISSIONING ACTIVITIES REPORT
(26th June 2015 to 09th August 2015)

Recommissioning Team,
Guhan M.R.
Yoginder Kumar J.
Mohideen K.P.K.
Raghunath G.L.
Annamalai R.
Rajkumar A.J.

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Unit-2 Overhaul Recommissioning Report (2015)

INDEX

A. Milestones

B. Modifications & Improvements

C. Surprises

D. Problems faced

E. Major works of departments

1. Turbine Maintenance

2. Boiler Maintenance

3. Electrical Maintenance

4. Control and Instrumentation

5. Ash Handling

6. Offsites

7. Acid Cleaning Protocol

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NTECL VALLUR
Unit-2 Overhaul Recommissioning Report (2015)

MILESTONES
S No Activity Date Time
1 Unit shutdown 22.06.2015 09:41
Overhaul declared start 26.06.2015 00:00
TDBFP-A Turbine Over Speed Test 23.06.2015 20:36
TDBFP-B Turbine Over Speed Test 25.06.2015 21:45
Main turbine barring stop 01.07.2015 08:36

Boiler acid cleaning start 03.07.2015 06:40

Boiler acid cleaning completion 07.07.2015 15:15
H2 purging with CO2, CO2 purging with Air 26.06.2015 04:35
Condenser Flood Test 28.07.2015 13:00
Boiler Internal Hydro test 27.07.2015 13:00
Generator Thread out 06.07.2015
Generator Thread in 18.07.2015

Main Turbine on Barring 07.08.2015 21:30

Generator air tightness test 04.08.2015 08:00
Boiler Final hydro test 03.08.2015 15:00
Boiler Air Leak Test & repair 04.08.2015 05:30
Boiler Light Up 06.08.2015 20:30
Safety valve floating 09.08.2015 21:00
Turbine Rolling 09.08.2015 23:00
Electrical Testing 09.08.2015 08:45
Unit Synchronisation 09.08.2015 16:45
Full Load Reached at 14.08.2015 16:35

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Unit-2 Overhaul Recommissioning Report (2015)

MODIFICATIONS & IMPROVEMENTS

1. Unit Emergency switchgear (UES) – Auto start and change over to DG set during Unit
/ Station blackout implemented successfully
2. Acid cleaning done in boiler as per recommended procedure of NETRA to avoid
repeated failures in boiler water wall
3. TDBFP A and B over speed test done successfully and operated @ 6116 & 5921
RPM respectively.
4. Both Auxiliary Oil pump of Main Turbine replaced with new model MATT platter pump
to solve vibration issues
5. CW Hot water and Cold water duct inspection done. Damaged Epoxy coating in cold
water duct recoated extensively.
6. Water wall tubes in First pass S panel bottom portion close to Bottom ash hopper had
got thinned extensively at many places.
7. Condenser tubes jet cleaning done. 2 no’s of tubes leakage identified and dummied
after condenser flood test
8. Seal oil tank makeup float replaced with new one
9. New vent valve provided near ACW inlet header to PHE’s for proper venting of ACW
system during initial charging of the system.
10. All GT cooler fan running status made through in DDCMIS and auto change over
checked and found ok
11. Integral Bypass Valve is provided in both TDBFP-A&B Exhaust Butterfly valve
12. Vacuum pumps cooling water connection changed from ACW system to TGDMCW
system.
13. CW inlet duct – Debris filter valve remote operation with inching command made
available to meet the Emergency situations during CW contingencies
14. HPH Extraction valves remote operation made through in inching mode.
15. Central Lube Oil Purification System (COPU) centrifuge was Re commissioned and oil
transfer from TDBFP’s to COT and Vice versa was done through centrifuge
successfully.

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Unit-2 Overhaul Recommissioning Report (2015)

SURPRISES
1. Both the debris filter got damaged during inspection same was welded with patches
repaired
2. Lot of slurry deposits found in SGPHE ACW inlet line. The pipe was almost half
choked with fine ash traces and the same was cleaned.
3. Thinning of S panel tubes near to Bottom ash hopper. Total 170 tubes replaced in S
panel based on thickness survey.
4. Eco hanger tube no 44 from LHS in hanger row 2, sponge ball test was carried out.
Tube chokage were observed. Hanger tube chokage were removed and replaced with
2mtr length tube.
5. Lot of rust debris found in LPH2, LPH3 and drain cooler inlet on the condensate
system side. LPH 1– 8 Kgs; LPH 2 – 5 Kgs; Drain cooler – 4 Kgs and LPH3 – 2 Kgs.
The same was removed and the LP heaters tube were cleared with jet cleaning.
6. During inspection of Deaerator, found 11nos of spray nozzle valves got dislocated and
the same yet to be attended. Also the level stand found in choked condition and
cleared.
7. ICV 2 gear box teeth/bearing found damaged during inspection
8. Oil flushing was carried out from 03.08.2015 11:30hrs. Lot of debris (Rust) particles
was found in line filters of bearing 5, 6 &7. Hence oil flushing extended for 4 days till
20.45 on 07.08.2015.
9. After electrical testing of turbo generator on 09.08.2015 @ 07:30, Main turbine
bearing vibrations at bearing no 5 started increasing up to 105 microns suddenly.
Hence, Machine was hand tripped, later rolled with improved parameters. Later it got
settled down.

PROBLEMS FACED
1. Generator H2 coolers isolation butterfly valves were passing heavily. Hence
TGDMCW was drained / Filled 4 times during cooler removal/fixing works.
2. During acid cleaning Boiler fill pump which was envisaged for purging was tripping
frequently on overload. Later found that whenever makeup water taken for solution
preparation, pump was tripping due to more flow. Later both the pumps were run
during the requirements and flow was throttled based on current of BFP.
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NTECL VALLUR
Unit-2 Overhaul Recommissioning Report (2015)

MAJOR WORKS DONE BY VARIOUS DEPARTMENTS

1. TURBINE MAINTENANCE:
 Main Turbine all bearings (1 to 7) were dismantled and inspected. Jacking oil
hoses of bearing {1, 2, 3 & 4} were replaced. Scoring marks were in Brg#4 and
was polished.
 LP turbine last stage blade trailing edge was found to be eroded. 5 nos balancing
weights of LP Turbine were found to be eroded and were replaced.
 Both HRH strainers 1 & 2 blanking plate welding crack was found and the same
was attended.
 MS Strainer -2 blanking plate welding crack was found and was attended.
 HP and IP Stop and Control valves servicing carried out in this shutdown
 Stop and Control valves Grafoil gland packing rings were replaced
 Overhauling of LPBP/HPBP valves servicing done
 Main oil tank is completely drained and oil is transferred to clean oil tank for
thorough cleaning. Main Oil tank cleaned and inspected.
 Auxiliary Oil Pumps - A&B were replaced by BHEL with Mather & Platt make
pumps.
 Deaerator Nozzles were inspected and 2 nozzles were found defective. Deaerator
trays were in dislodged condition and the same was assembled back.
 Deaerator Standpipe LP lines were in choked condition and was cleared.
 TDBFP A/B - Oil injection test was carried out and bolts were not acted during Oil
Injection. Actual over Speed was occurred at 6121 rpm and 5921rpm.
 TDBFP-A BFP DE Journal bearing return oil line was in choked condition and it
was observed no oil flow in the return line and oil was leaking from DE pedestal.
Line was air blown and debris like gaskets, sealant were removed.
 TDBFP 2A SH NRV passing was observed before overhaul. NRV was serviced.
SH NRV was replaced
 Integral bypass valve was provided for Exhaust butterfly valve to facilitate vacuum
pulling of TDBFP’s

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Unit-2 Overhaul Recommissioning Report (2015)
 TDBFP A/B Seal Steam and Leak Steam Isolation valves were reported for
jamming and valve servicing was done and Seal Steam lines blowing was done at
17 m
 Both TDBFP’s Oil Tank was completely drained and oil was transferred to COT.
Rust particles were observed inside tank and all debris was removed.
 MDBFP - BFP suction strainer mesh was in damaged condition and BFP suction
strainer is replaced with spare one.\
 Hot well is completely drained and all the debris was removed.
 MOT Coolers, Primary Water Coolers, TDBFP (A&B) Coolers, MDBFP Lube oil &
Working Oil coolers were opened (rust particles were choking Cooler tubes) and
all tubes were cleaned thoroughly.
 Before Shutdown, it was observed Condensate flow is less via DC & LPH – 1.
During Overhauling, Drain cooler, LPH-1, LPH-2 and LPH-3 man hole doors were
opened. It was observed Drain cooler and LPH-1 was in partially choked and all
the tubes of all heaters were cleaned thoroughly.
 Primary water Ion exchange unit resins were replaced. Passing was in DM Make
up valve to Primary water tank and subsequently another isolation valve was
provided.
 Primary water pump -2A high vibration was reported and alignment checks and
correction was done.
 Vacuum Pumps cooling water system shifted from ACW cooling water system to
TG DMCW water system.
 LPT Lead Diaphragm modification done to facilitate easy replacement of
diaphragm
 All PHE’s cleaned and ACW inlet and outlet valves serviced
 ALL ACW pumps servicing done

2. BOILER MAINTENANCE:

 Total HP joints1056 in Unit#2 Overhaul.

 In-situ Inspection and thickness measurement of the following areas were carried
out as per CC-OS guidelines. Total 29017 survey points were measure in
 Corrosion mapping of following areas were carried out as per the CC-OS
guidelines. No abnormalities were found. Total scanned area is 12190 mts

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Unit-2 Overhaul Recommissioning Report (2015)
 Based on thickness survey, due to thinning of tubes in S panel 170 nos of tubes
were replaced in 8.5mtr elevation..
 S panel bottom seal trough wire mesh was in damaged conditions in all sides.
Total 24 no’s of wire mesh were replaced.
 Based on the failure history of LTSH hanger no 12 from LHS, sponge ball test and
boroscopic inspection was carried out and no foreign materials were found.
 BOILER DRUM & RING HEADER – All internals were removed, inspected,
cleaned and fitted back after joint inspection with operation/Chemistry and PP.
 The following valves were serviced and gland packing replaced. B111, B110, SD
008, S036, S017, S015
 The following safety valves were serviced: SH – SV7&8, Drum – SV3&6, HRH –
18 & 20.
 S panel area total 5 no’s of hangers were in loose conditions and turn buckles
tightened.
 All corner SADC flaps were checked from inside wind box and jamming was
observed. SADC flaps freeness witnessed along with operation engineer.
 All SADC operation was checked by C&I maintenance.
 All Mills and feeders overhauling and servicing done
 All HAD’s/CAD’s and HAG’s/CAG’s overhauling done
 All pending duct bracings in Air/Flue gas path were completed
 ID/FD/PA fan’s overhauling done
 Seal air fan and AC scanner air fan servicing done.
 APH’s water washing done and all baskets were removed, cleaned and seal
setting done

3. ELECTRICAL MAINTENANCE:

 104 Nos. of SF6 Circuit breakers (ABB make) - Servicing and Overhauling done in
all11KV/3.3KV HT switchgears through OEM-ABB India ltd.
 Insulation painting of class A and class B type are done in HT switchgears in front of
3.3 KV and 11 KV ht Switchgear. Old Insulation rubber mats are removed.
 Closing interlock modified in Changeover logic from Unit Bus to Station bus. (i.e.
Either Normal ST incomer / Tie Breaker from other unit station bus -ON feedback AND
Tie breaker in Station bus ON Feedback provide close permissive for Tie breaker in
Unit bus.)

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Unit-2 Overhaul Recommissioning Report (2015)
 HT Motors Overhauling was done in 5 Nos such as PA A/B, FD FAN A/B and
SGDMCW B
 PM jobs were carried out in 21 No’s of HT Motors
 All LT switchgears Overhauling done except DCDB
 GT,ST,UT & UAT 2A&2B Transformer testing done
 Generator Overhauling and servicing done with OEM BHEL
 All hydrogen coolers and Exciter coolers cleaning and hydro test done
 Generator ATT successfully completed

4. CONTROL &INSTRUMENTATION

 TSI pick-ups calibration done

 All LLD’s calibration completed.
 All SOE points made through and checked
 MIL Valves 40/42 calibration done
 45/45 LIE & 35/35 LIR Cleaned
 All 45/45 LIE & 35/35 LIR cleaned
 All HAG’s/CAG’s and HAD’s/CAD’s servicing and calibration done
 HPBP OSU servicing and Checking Completed; HPBP & LPBP System, All Actuators
Servicing Completed
 All Igniters and flame scanners serving and calibration done
 All SADC dampers inspection and adjustment done

5. ASH HANDLING MAINTENANCE:

 Bottom ash hopper refractory inspection & repair work done

 All clinker grinders servicing done
 Bottom ash sampling line provided at ejector discharge for chemistry requirements
 BALP flushing isolation valve passing was attended by replacing the valve
 All vacuum pumps, collector tanks, air washers servicing done
 ESP all passes Fields & Hoppers water washing, inspection and rectification done

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Unit-2 Overhaul Recommissioning Report (2015)
6. OFFSITES

 CW 2A Pump replacement done by WPIL

 Entire Cold water duct and Hot water duct till CW pump house PU coating damages
were rectified completely
 Cooling Tower 2A and 2B cold water basin cleaned and all the sludge’s were removed
 All CT fans PM jobs carried out by EMD/OFS
 CT cell 2A1and 2A2 civil works- Epoxy coating done for reducing seepages in tower

7. ACID CLEANING PROTOCOL:

Acid cleaning was carried out from 02.07.2015 to 10.07.2015 due to repeated
Boiler tube leakage in Water wall area as per NETRA recommendation. The Signed
protocols including the timings are as given below.

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