Efficiency & Operation related points to be attended during

Sr. No. System Sub- System Equipment Department

1 Turbine Condensate Ckt CEP 3A & 3B TMD

2 Turbine Condensate Ckt CEP o/l & Dea i/l Flow transmitter C&I
3 Turbine Vacuum system Vacuum Pump C&I
HP & LP bypass valve
4 Turbine HP & LP bypass Mech
HP & LP bypass drain & spray Valve
HP & LP bypass valve
5 Turbine HP & LP bypass C&I
HP & LP bypass Spray Valve

6 Turbine HP & LP bypass HP bypass drain line Mech

7 Turbine HP Heaters HP heaters Mech

8 Turbine Condenser hotwell TMD
9 Turbine Condenser Condenser tubes TMD
10 Electrical TG set Generator TMD
11 BOP Condenser CW system BOP
12 Turbine Feed water Circuit Recirculation valve TMD
13 Turbine Feed water Circuit Dearator TMD
14 Turbine lube oil system tank TMD
15 Turbine LP turbine Cross over pipe TMD/C&I
16 Boiler Economiser inlet Economiser inlet temperature probe C&I

17 Boiler Economiser inlet Economiser inlet Pressure transmitter C&I

18 Boiler ID/FD/PA fans Flow measurement point Mech
19 Boiler Furnace Flue gas system BMD

20 Boiler Burners Combustion system BMD

21 Boiler Furnace Exit temperature C&I

22 Boiler FD Fan Secondary Air C&I

23 Boiler FD Fan Secondary air Flow C&I

24 Boiler PA fan Primary Air C&I

25 Boiler PA fan Primary Air Flow C&I
26 Boiler ESP Flue gas system C&I
27 Boiler Oxygen Measurement Flue gas system BMD/C&I
28 Boiler Oxygen Measurement Flue gas system BMD

29 Boiler Coal mills pipe orifice BMD

30 Boiler Coal mills Mill Classifier BMD

31 Boiler Furnace steam & water circuit tubes BMD

32 Boiler Air & flue gas system Fans BMD

33 Boiler Furnace steam & water circuit tubes BMD

34 Boiler Air & flue gas system APH BMD

35 Boiler Furnace Coils & water wall BMD
36 Boiler PA & SA circuit Duct BMD
37 Boiler Steam circuit Safety valves BMD
38 Boiler Flue gas Path ESP BMD
39 Boiler Flue gas Path Furnace external BMD
40 Boiler Steam circuit Drum BMD
41 Boiler Combustion system Burners BMD
42 Boiler Pressure parts Hangers & Supports BMD
43 Boiler Pressure parts Expansion indicatirs BMD
44 Boiler Furnace Air Tightenss test BMD
45 Boiler ESP ESP inlet/Outlet gates BMD
46 Boiler Coal Bunkers Coal Bunkers CHP
47 Boiler Primary Air Fans PA Fans BMD
48 Boiler Steam circuit BCP BMD
49 Boiler Coal Mills Coal Feeders C&I
50 Boiler Coal Mills Primary Air Flow BMD
51 Boiler Coal Mills Mill inlet/discharge pipes BMD
52 Boiler Coal Mills Mill reject system BMD
53 Boiler Oil firing circuit HFO system BMD/C&I/Elec
54 Boiler Boiler proper steam & water circuit drains BMD
55 Boiler Flue gas Path Induced draft fan (ID Fan-A) BMD
56 BTG Feed water Circuit Flow transmitters C&I
57 BTG OCCW & CCCW PHE & coolers TMD
58 BTG Insulation Boiler/turbine BMD/TMD
59 BOP Cooling tower CT Basin BOP
60 BOP Cooling tower CT fills BOP
61 BOP Cooling tower RH & tempearture monitoring BOP C&I

62 Electrical Aux. Power circuit Energy meter Elect

63 Electrical Generater Energy meter Elect
64 Electrical Generater AVR Elect
65 Turbine Turbine Governinig System Control Valves TMD/C&I
66 Turbine Condensate Polishing Unit Mixed Bed TMD
67 Turbine Thrust bearing Temp.Transmitters C&I
68 Turbine Aux. PRDS Drain line TMD
69 Turbine Turbine Supervisory system TSR relay C&I
70 Turbine Hotwell makeup circuit Hotwell makeup valve TMD
71 Turbine Aux. Cooling Water circuit OCCW Pump TMD
72 Turbine lube oil system Lube oil coolers TMD
 Efficiency & Operation related points to be attended during Unit-3 COH
Activities to be carried out Thrust Area
CEP de-staging from 5 stage to 4 stage Included in TMD budget Aux. Power consumption
Flow trans calibration & matching of CEP o/l & Dea I/L flow transmitter NA Turbine Heat rate
Rota meter to be provided in vacuum pump outlet Included in C&I budget Turbine Heat rate
Passing to be arrested & valve replacement if required. Included in TMD budget Turbine Heat rate

In Spray line flow tranmitter to be provided. Included in C&I budget Turbine Heat rate

HP bypass before drain line to be connected to MSV drain to establish the flow & avoid the condensate
Turbine Heat rate
accumulation in HP bypass valve.
HP heaters inspection required for any tube leakage in Heaters. Turbine Heat rate
Cleaning of hotwell & flood test Turbine Heat rate
Jet cleaning of condenser tubes Turbine Heat rate
Hydrogen Drop rate is more in Unit-3 so leakge to be arrested safety
CW Inlet & Outlet duct inspection & cleaning to be carried out Turbine Heat rate
Feed water recirculation valves passing to be arrested APC & Cycle efficiency
feed storage tank & dearation system cleaning to be done water chemistry
MOT cleaning & oil flushing Turbine Heat rate
Pressure transmitter to be provided at LP inlet cross over pipe Turbine Heat rate
Extra Temperature probe installation is required for accurate measurement of eco inlet temperature. Boiler efficiency

Pressure transmitter to be provided at Eco inlet. Boiler efficiency

Flow measurement points to be provided for calculation fan efficency Fan Efficiency
Clean air velocity test to be performed Boiler Efficiency

Burner alignment to be check Boiler Efficiency

Furnace exit temperature Boiler Efficiency

Secondary Air temp probe at FD fan outlet & and APH inlet required.
Fan Efficiency
Secondary air pressure transmitter at APH APH i/l.

Secondary air flow measurement. Fan Efficiency

Primary air temperature probe at PA o/l required. APH performance

PA fan flow meter at PA outlet Fan Efficiency
At ESP inlet Flue gas pressure transmitter & temperature probe is required. Fans loading/APC
O2 analyser at goose neck area or FG entering 2nd pass is required. Boiler Efficiency
Freeness of all measuring ports at APH inlet &access Platform required. Boiler Efficiency

Mill Dirty air flow test to be conducted in all coal mills Boiler Efficiency

All mills classifier inspection & rectification/replacement to be done. Boiler Efficiency

Tube thickness survey and thickness mapping in identified areas to be carried out & if required tubes
Boiler Efficiency
to be replaced.
Fans internal inspection & silencer cleaning Aux. Power consumption
Oxide scale measurement in SH & RH coils is to be done once in two years and remaining life of tube is
to be assessed Boiler Efficiency

APH internal inspection & seal replacement & basket maitenence & other required repairs to be
carried out APC & Boiler efficiency
Water washing of boiler & APH Boiler Efficiency
Air Duct leakage inspection and leakage arresting Boiler Efficiency & APC
Boiler Efficiency & Cycle
All safety valve servicing to arrest the steam passing makeup
ESP and GD screen internal inspection & repair as per requirement Environment
Pent house cleaning and leakage arresting work Boiler Efficiency
Drum internal inspection Boiler Efficiency
Coal / Oil burners inspection and repair Boiler Efficiency
To be restored to orignal position System Reliability
To be restored to orignal position System Reliability
Boiler air tightness test Boiler efficiency
ESP All Gate operation readiness System Reliability
All coal bunker internal inspection & strenghtninig System Reliability
both PA fan internal inspection required due to taking high current. Aux. Power consumption
All BCP DP transmitter line flushing. System Reliability
Feeder inlet Gate limit switch indication System Reliability
All Coal Mill HAD, CAD & Mix air duct replacement required. Boiler Efficiency
Mill discharge Pipe / Centre pipe replacement due to heavy leakages Boiler Efficiency
Mill Reject system water drain completion ( Overflow tank line connection) System Reliability
HFO System removal completely Boiler Efficiency
Boiler water & steam side all drain valve lapping required. Boiler Efficiency
ID Fan # A motor DE bearing inspection required due to maintaining high. System Reliability
All flow transmitter inspection & calibration is required System Reliability
Heat Exchangers cleaning to be done System Reliability
Week & missing insulation to be replaced Boiler Efficiency
cleaning of CT basin Turbine Heat rate
cleaning of fills & replacement of damaged fills Turbine Heat rate
CT performance /Turbine
24 hours monitoring of DBT,WBT & RH in DCS to calculate CT performance
Heat Rate
All energy meters calibration required for accurate reading measurements DGR Data/MIS
Energy meters calibration required DGR Data/MIS
PSS tuning to be done System Reliability
HPCV 3 & 1,2,4 internal inspection & maitenence System Reliability
CPU MB bypass line MOV & MIV lapping required. System Reliability
Turbine thrust bearing & temperature transmitter healthiness inspection. System Reliability
IP & LP steam line common aux header atmospheric drain line required with proper approach. Turbine Heat rate
  TSR system availability. System Reliability
Hot well make-up line control station all valve lapping required. turbine Heat rate
OCCW outlet common discharge header, MIV required for emergency isolation. System Reliability
Lube oil cooler cooling line i/l valve dia increase System Reliability
 Justification
Unit # 2 CEP De-staged from 5S – 4S, specific power reduced from 3.8 KW/MW to 3.1 KW/MW, Achieving
a power consumption reduction of 10 Mwhr/Day.
To calculate the accurate HR with the help of iteration method.
Will be helpful for identifying the air ingress into the syste,
Will be helpful in maintaining heat rate and to avoid unaccountable losses.

To calculate the passing in HP bypass valve.

To avoid HP bypass valve passing.

Presently ECO i/l teperature is maintaining approx 4 to 5 deg. below design value.
Improvement in condensate parameter & avoid any scaling & blockage in the associated system.
THR is icreased by 19 kcal/kwh if vacuum drops by 1 kpa
Reduction in hydrogen consumption & safety of the man & machine
Better heat transfer for Vacuum improvement
To improve cycle efficiency & reduce the APC
To improve feed water quality & avoid stariner chocking
Smooth rotation & low bearing temp
To calculate LP turbine efficiency.
One nos already installed, one extra temp probe is required for retendency & reliability, being a important
point for calculating unit efficiency.

To calculate the Feed water enthalpy at eco inlet.

FD/PA fans ports already installed, port installation in ID fans is required.
To reduce the tube erosion in second pass of boiler which leads to tube leakage. To reduce to dry flue gas
loss
Burner alignment to be check for imbalance in furnace exit temperature & to ensure proper fire ball angle
in furnace.
Helpful in remote monitoring the Furnace exit flue gas temperature and maintain within limit of Ash-
Initial deformation temperature.

It is to calcualte the fan efficency & to find out any duct leakages up to APH i/l.

Presently flow transmitter is installed in boiler at wind box area & finding difficult to evaluate individual
fan performance.
To evaluate the temperature gain of PA at APH outlet.
To evaluate fan efficiency.
To identify any leakeges in duct & to reduce the fans loading.
To identify the air leakages in the 2nd pass.
Grid measurement at of O2 at APH inlet.
To balance the air velocity across all four discharge pipes to improve mill performance & achieve better
combution
50 mesh retention is very high in Mill-A,B& C leads to high unburnt, and secondary comustion of fuel leads
to high spray flow.

To eliminate the possibillity of boiler tube leakage

Reliability & APC reduction

Better heat transfer for boiler efficiency improvement

Minimize the air leakage & improve the APH effectiveness

Better heat transfer for boiler efficiency improvement
Load reduction on fans & better APH performance
Boiler efficiency improvement
Better ESP performance & ASH coolection
Boiler efficiency improvement
Boiler efficiency improvement
Boiler efficiency improvement
Boiler healthiness
To check proper expansions
to check gor any leakages in furnace to avoid any air ingress in boiler/pent house ash deposition.

Flow transmitter readings are mismatched

better heat exchange & cooling capability
Energy audit insulation report is available with us for finding weak & damaged insulation.
To improve the CW wate quality & CT performance
To improve cooling tower effectiveness
Accurate day performance of CT can be measured, presently taking manual readings at 8am,2pm & 10 pm.
Routine maintainence/WRLDC compliance for calculating line Export capacity.