UNIT-10 WINTER OUTAG

NOVEMBER - D

Notification Work Order Activity

Sr. No.
Number Number Type

1 640001037 4500002481 CM
2 640001006 4400000851 CM

3 640001005 4400000857 CM

4 640000952 4400000890 CM
5 640000945 4400000698 CM

6 640000941 4400000692 CM

7 640000931 4400000681 CM
8 640000813 4400000871 CM
9 640000739 4400000867 CM
10 640000654 4400000866 CM

11 640000131 4400000860 CM

12 640000937 4400000886 CM
13 640000818 4400000626 CM
14 640000546 4400000899 CM

15 640000947 4400000889 CM

16 640000939 4400000887 CM
17 640000819 4400000872 CM

18 640001068 4400000900 CM

19 640001071 4400000832 CM
20 640001063 4400000891 CM
21 640001029 4400000839 CM
22 640001013 4400000771 CM
23 640001012 4400000770 CM
24 640000985 4400000856 CM
25 640000973 4400000842 CM
26 640000966 4400000739 CM
27 640000767 4400000550 CM
28 640001009 CM
29 640001010 CM
30 640001011 CM
31 640000757 4400000551 CM
32 640000546 CM
33 640000545 CM
34 640000483 4400000383 CM
35 640000484 4400000386 CM
36 640000441 4400000394 CM
37 CM
38 CM
39 PM
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41 PM
42 PM
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UNIT-10 WINTER OUTAGE JOBS MASTER PLA
NOVEMBER - DECEMBER 2023

Planned
Work Description Priority
Start

U10 CEP-A Oil Leakage Rectification

U10 Debris Filter Lower Half Leakage Rectification P1 6-Nov-23

U10 BFP-A observed High X Vib of NDE Bearing of motor ~3.2mm/sec (Alignment
P1 12-Nov-23
Required)
U10 HP bypass v/v upstream vent v/v passing observed
U10 CEP B disc flange dropwise leakage
U10 atm tank pump A CCCW inlet reg leak (Seepage observed from regulator set
screw)
U10 Vacuum pump-B (MAJ) Gland leakage
U10 HP CBD leakage from CV side (Leakage is from bonnet) P1 7-Nov-23
U10 Stator water resin tank flexible pipe
U10 IPB Fan-A NRV Need to check
U10 HP ECO drain iso vlv passing (Valve passing was not checked because Unit
was operational)
Unit 10 IP drum PSV leakage observed from bonnet
Unit 10 perf htr IP water support damage
Unit 10 HP saturated steam valve passing
U10 HP drum PSV passing observed (stem observed from PSV drain point and
gland)
U10 Cond. to LP eco inlet PSV passing (water found dripping)
U10 Perf htr IP water supply PRV passing
U 10 IP CV, Drain Valve Steam Leakage (Steam leakage Observed from Drain line
of U 10 IP Main Control Valve)
U10 HRH drain line leakage near ATM tank
Gland Leakage frm IP saturated steam v/v
U-10 vacuum pump DE bearing abnormal observed (DE Bearing Greasing)
U2 IP startup DRAIN MOV PASSING ISSUE
U2 HP startup DRAIN MOV PASSING ISSUE
Gen-10 Liquid detectr sight glas has oil
U-10 Vacuum tank temperature high
Salts deposition to be removed in MPB-1
HRSG-10 HP evap drain MOV gland leak
U-10 IP evap drain mov passing issue
U-10 IP startup drain mov passing issue
U-10 HP startup drain mov passing issue
Unit-10 CEP-A self sealing line water flow abnormal sound observed.
Unit 10 Hp saturated steam valve passing
HPS steam line passing Unit 10
HP Drum sampling flushing valve passing
HRSG1 HPSupheated sampling valve Passing
HRSG-10 HP SH Flush V/v is passing
CCCW Pump-B Leakage Rectification & Alignment P1 8-Nov-23
CCCW Expansion Tank Hose Repair P1 6-Nov-23
U10 Vacuum Pump-A NDE Bearing Grease Replacement
U10 Vacuum Pump-A Bearings Grease Replacement
U10 Vacuum Pump CCCW Heat Exchanger-A Cleaning
U10 Vacuum Pump CCCW Heat Exchanger-B Cleaning
OCW Pump-A Bearings Grease Replacement & Cleaning
OCW Pump-B Bearings Grease Replacement & Cleaning
OCW Pump-C Bearings Grease Replacement & Cleaning
CCCW Pump-A Bearings Grease Replacement & Cleaning
CCCW Pump-C Bearings Grease Replacement & Cleaning
U10 Debris Filter-A Internal Inspection & Chemical Coating
U10 Debris Filter-B Internal Inspection & Chemical Coating
U10 Ball Catcher-A Internal Inspection & Chemical Coating
U10 Ball Catcher-B Internal Inspection & Chemical Coating
GT10 Air Intake (Filter House (MBL) Inspection
U10 Condenser Water boxes Inspection
U10 CEP Pump-A Oil replacement
U10 CEP Pump-B Oil replacement
U10 Lube Oil Vapour Exhauster Inspection & Filters Replacement
HRSG-10 Inspection
HRSG-10 HP Drum Inspection
U10 IP Drum Inspection
U10 LP Drum Inspection
CCCW HX-A Plates Cleaning
CCCW HX-B Plates Cleaning
CCCW HX-C Plates Cleaning
U10 BFP-A manual rotation
U10 BFP B manual rotation
U10 Vacuum pump A manual rotation
U10 Vacuum pump B manual rotation
U10 LP recirculation pump A manual rotation
U10 LP recirculation pump B manual rotation
U10 BFP-A Lube Oil Skid Cleaning
U10 BFP-B Lube Oil Skid Cleaning
U10 ST Hydraulic Skid Cleaning & Silica Inspection
U10 GT Hydraulic Skid Cleaning
U10 Generator Seal Oil Skid Cleaning
U10 Generator Stator Water Skid Cleaning
U10 ST Turning Gear Inspection
U10 GT Turning Gear Inspection
U10 Condenser Rupture Disc Inspection
HRSG-10 PSVs Trevitesting
HRSG-10 PSVs Servicing
HRSG-10 All Manual & Motorized Valves Servicing & Functional Checks
U10 Condenser & Hotwell Inspection
U10 ST Last Stage Blades Inspection
Bladders Nitrogen Pressure Checking
GT & ST Hydraulic Hoses Inspection
Hydraulic Skids Coupling Inspection
Lube Oil Tank Return Strainer Inspection
U10 Water Box Vacuum Pump piping replacement
Gland Condenser Fan Vibration Monitoring
STER PLAN

Actual Actual Completion

Planned Finish Duration
Start Finish Percentage

11-Nov-23

13-Nov-23

13-Nov-13
10-Nov-23
10-Nov-23
 UNIT-10 WIN

Notification Work Order Activity

Sr. No.
Number Number Type

1 640001037 4500002481 CM

2 640001006 4400000851 CM

3 640001005 4400000857 CM
4 640000952 4400000890 CM

5 640000945 4400000698 CM

6 640000941 4400000692 CM

7 640000931 4400000681 CM

8 640000813 4400000871 CM
9 640000739 4400000867 CM

10 640000654 4400000866 CM

11 640000131 4400000860 CM

12 640000937 4400000886 CM

13 640000818 4400000626 CM

14 640000546 4400000899 CM
15 640000947 4400000889 CM

16 640000939 4400000887 CM

17 640000819 4400000872 CM

18 640001068 4400000900 CM

19 640001071 4400000832 CM

20 640001063 4400000891 CM
21 640001029 4400000839 CM

22 640001013 4400000771 CM

23 640001012 4400000770 CM

24 640000985 4400000856 CM

25 640000973 4400000842 CM

26 640000966 4400000739 CM
27 640000767 4400000550 CM

28 640001009 CM

29 640001010 CM

30 640001011 CM

31 640000757 4400000551 CM
32 640000546 CM
33 640000545 CM
34 640000483 4400000383 CM
35 640000484 4400000386 CM
36 640000441 4400000394 CM
37 CM
38 CM

39 PM

40 PM

41 PM
42 PM

43 PM

44 PM

45 PM
46 PM

47 PM

48 PM
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50 PM

51 PM
52 PM

53 PM

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78 PM
79 PM
80 PM
81 PM
82 PM
83 PM
84 PM
85 PM
86 PM
87 PM
88 PM
89 PM
 UNIT-10 WINTER OUTAGE JOBS
NOVEMBER - DECEMBER 202

Work Description

U10 CEP-A Oil Leakage Rectification

RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEP oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
Record observations after pump has taken into operation.
U10 Debris Filter Lower Half Leakage Rectification
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Debris Filter manways opening.
Debris Filter functional checks.
Debris Filter internal inspection.
Surface preparation for doubler plate welding.
Doubler plate welding.
NDT (DPT) check for weld joint assessment.
Debris Filter manways closing with the presence of OPS team.
Remove temporary arrangements made for leak
Perform complete area housekeeping after work completion.
Clear PTW
U10 BFP-A observed High X Vib of NDE Bearing of motor ~3.2mm/sec (Alignment
Required)
RA,WMS submission and PTW acquisition.
Pump coupling guard removal.
Coupling spacer and shim packs removal.
Measurement of alignment reading.
Pump to motor alignment.
Motor CCCW connections removal (if required)
Fill alignment protocol after alignment completion
Coupling spacer and shim packs installation.
Pump coupling guard installation.
Perform complete area housekeeping after work completion.
 Clear PTW
U10 HP bypass v/v upstream vent v/v passing observed
RA,WMS submission and PTW acquisition.

Welding of new high pressure valve in addition to existing vent valves

NDT (DPT) check for weld joint assessment.

Perform complete area housekeeping after work completion.
Clear PTW
U10 CEP B disc flange dropwise leakage
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Flange bolts tightening
Scaffolding removal.
Perform complete area housekeeping after work completion.
Clear PTW
U10 atm tank pump A CCCW inlet reg leak (Seepage observed from regulator set
screw)
RA,WMS submission and PTW acquisition.
Regulator disassembly
Gasket (Teflon) installation
Regulator assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum pump-B (MAJ) Gland leakage
RA,WMS submission and PTW acquisition.
Gland pusher removal.
Gland packing inspection.
Gland packing replacement (if required)
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP CBD leakage from CV side (Leakage is from bonnet)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Valve actuator removal
Valve disassembly (to expose bonnet)
Valve bonnet inspection
Valve bonnet On Site Machining
Valve re-assembly (with new gaskets)
Valve actuator assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 Stator water resin tank flexible pipe
RA,WMS submission and PTW acquisition.
Hose Pipe replacement with new one.
Perform complete area housekeeping after work completion.
Clear PTW
U10 IPB Fan-A NRV Need to check
RA,WMS submission and PTW acquisition.
NRV passing check by keeping Fan-B in operation.
If passing found, duct will be dismantled.
Check for NRV servicing or Install new NRV
Perform duct re-assembly.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP ECO drain iso vlv passing (Valve passing was not checked because Unit
was operational)
RA,WMS submission and PTW acquisition.
Valves cleaning, greasing and servicing.
Valves operational check
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 IP drum PSV leakage observed from bonnet
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
Rigging arrangement to lift PSV.
PSV cleaning and servicing.
Bonnet inspection for steam cuts (if any)

Bonnet gasket replacement.

PSV re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 perf htr IP water support damage
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Support welding
Scaffolding removal.
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 HP saturated steam valve passing
RA,WMS submission and PTW acquisition.
Sampling valve replacement with new one.
NDT (DPT) check for weld joint assessment.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP drum PSV passing observed (stem observed from PSV drain point and
gland)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
U10 Cond. to LP eco inlet PSV passing (water found dripping)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
PSV disassembly
Plug and seat inspection
Seat lapping (if required)
PSV cleaning and servicing.
Perform complete area housekeeping after work completion.
Clear PTW
U10 Perf htr IP water supply PRV passing
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
PRV disassembly

PRV calibration at REETS Lahore Workshop

PRV re-assembly after calibration

Perform complete area housekeeping after work completion.
Clear PTW
U10 IP CV, Drain Valve Steam Leakage (Steam leakage Observed from Drain line
of U 10 IP Main Control Valve)
RA,WMS submission and PTW acquisition.
Piping insulation removal.
Valve insulation removal.
Lekage point identification.
Leakage rectification.
Piping insulation installation.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HRH drain line leakage near ATM tank
RA,WMS submission and PTW acquisition.
Piping insulation removal.
Valve insulation removal.
Lekage point identification.
Leakage rectification.
Piping insulation installation.
Perform complete area housekeeping after work completion.
Clear PTW
Gland Leakage frm IP saturated steam v/v
RA,WMS submission and PTW acquisition.
 Gland replacement
Perform complete area housekeeping after work completion.
Clear PTW
U10 vacuum pump DE bearing abnormal observed (DE Bearing Greasing)
RA,WMS submission and PTW acquisition.
Review Vibration Analysis report
Coupling guard removal
Pump to motor alignment check
Motor removal
Coupling hub removal
DE bearing grease replacement
DE bearing replacement
Coupling hub re-installation
Pump to motor alignment
Fill alignment protocol after alignment completion
Coupling guard installation
Perform complete area housekeeping after work completion.
Clear PTW
U2 IP startup DRAIN MOV PASSING ISSUE
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U2 HP startup DRAIN MOV PASSING ISSUE
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
Gen-10 Liquid detectr sight glas has oil
RA,WMS submission and PTW acquisition.
Drain Oil present in sight glass
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum tank temperature high
RA,WMS submission and PTW acquisition.
CCCW HX inspection and cleaning
Perform complete area housekeeping after work completion.
Clear PTW
Salts deposition to be removed in MPB-1
 RA,WMS submission and PTW acquisition.
Perfrom skid cleaning
Perform complete area housekeeping after work completion.
Clear PTW
HRSG-10 HP evap drain MOV gland leak
RA,WMS submission and PTW acquisition.
Gland replacement
Perform complete area housekeeping after work completion.
Clear PTW
U-10 IP evap drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U-10 IP startup drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U-10 HP startup drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
Unit-10 CEP-A self sealing line water flow abnormal sound observed.
Unit 10 Hp saturated steam valve passing
HPS steam line passing Unit 10
HP Drum sampling flushing valve passing
HRSG1 HPSupheated sampling valve Passing
HRSG-10 HP SH Flush V/v is passing
CCCW Pump-B Leakage Rectification & Alignment
RA,WMS submission and PTW acquisition
Review Vibration Analysis report
Coupling guard removal
Leakages rectification
Pump to motor alignment check
Perfrom alignment
Fill alignment protocol after alignment completion
Coupling guard installation
 Perform complete area housekeeping after work completion.
Clear PTW
CCCW Expansion Tank Hose Repair
RA,WMS submission and PTW acquisition
Hose dismantling
Hose repairing (from local market)
Hose re-installation
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump-A NDE Bearing Grease Replacement
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump-A Bearings Grease Replacement
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease (NDE bearing)
Apply new grease on bearing as per OEM recommendation
For DE Bearing
Pump to motor alignment check
Motor removal
Coupling hub removal
DE bearing grease replacement
Coupling hub re-installation
Pump to motor alignment
Fill alignment protocol after alignment completion
Bearing end cover installed
Coupling guards installed
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump CCCW Heat Exchanger-A Cleaning
RA,WMS submission and PTW acquisition.
Disassembly of heat exchanger
Inspection & cleaning of HX plates
Inspection of gaskets
Installation of gaskets
 Assembly of heat exchanger
Perfome complete area housekeeping after work
Clear PTW
Leak test will perform
U10 Vacuum Pump CCCW Heat Exchanger-B Cleaning
RA,WMS submission and PTW acquisition.
Disassembly of heat exchanger
Inspection & cleaning of HX plates
Inspection of gaskets
Installation of gaskets
Assembly of heat exchanger
Perfome complete area housekeeping after work
Clear PTW
Leak test will perform
OCW Pump-A Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical seal flushing
lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
OCW Pump-B Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical seal flushing
lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
OCW Pump-C Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
 Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical seal flushing
lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
CCCW Pump-A Major Overhauling
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical seal flushing
lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
CCCW Pump-C Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical seal flushing
lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
U10 Debris Filter-A Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Debris filter internal cleaning
Debris filter internal inpection (If found damage report to lead)
 Repair the damage
Debris filter functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Debris Filter-B Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Debris filter internal cleaning
Debris filter internal inpection (If found damage report to lead)
Repair the damage
Debris filter functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Ball Catcher-A Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Ball Catcher internal cleaning
Ball Catcherr internal inpection (If found damage report to lead)
Repair the damage
Ball Catcher functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Ball Catcher-B Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Ball Catcher internal cleaning
Ball Catcherr internal inpection (If found damage report to lead)
Repair the damage
Ball Catcher functional test
Check gasket , if found good condition.
 Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
GT10 Air Intake (Filter House (MBL) Inspection
RA,WMS submission and PTW acquisition.
Inspection of all filter modules
Inspection of all evap pad modules
Inspection of clean room
Any damage found, repair it.
Filter modules internal cleaning
Perfome complete area housekeeping after work
Clear PTW
U10 Condenser Water boxes Inspection
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Water box internal cleaning
Water box internal inpection, if found damage report to lead (hold)
Inspection of anode, if found damage report to lead (hold)
inpection of tubes, If found choked report to lead (hold)
Check gasket, if found good condition.
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 CEP Pump-A Oil replacement
RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEO oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
Record observations after pump has taken into operation.
U10 CEP Pump-B Oil replacement
RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEO oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
 Record observations after pump has taken into operation.
U10 Lube Oil Vapour Exhauster Inspection & Filters Replacement
RA,WMS submission and PTW acquisition.
Perform vapour exhauster complete cleaning
Inspect filters condition
Replace filters (air and oil) as per condition

HRSG-10 Inspection
RA,WMS submission and PTW acquisition.
Flue Gas Side
Open all the gas duct manholes. Be sure all local and state safety practices
have been implemented and that the unit is safe for entry and service
Fill the entire HRSG with water and pressurize to inspect for leaks.
Inspect the interior of the HRSG. At the harps, look for deposits, erosion, or
damage to the fins and tubes
In the gas duct, look for damaged or missing liner casing, clips and insulation
Check for loose or detached gas passing plates located at the bottom, top, and side
of each module
Look for deposits built up on the tubes, particularly at the cold end of the HRSG
Units with carbon build-up on the exterior of the finned tubes may be air blowed or
dry ice washed.
Inspect all external surfaces of the HRSG, piping, electrical and pneumatic
service lines and the access platforms for structural integrity
Gas Duct Manhole Usage and Gasketing
Clean the old bolting tape from both surfaces with a wire wheel grinder
Use a bead of silicone RTV or other suitable material to hold new bolting tape to
the boiler casing

Bolting tape shall be a minimum of 3 mm thick and 45 mm wide. The bolting tape
shall lay flat against the surfaces with no laps or gathering of the material. Teflon
impregnated material or semi-liquid coating shall not be used

Align the door and finger tighten all bolts. Continue tightening bolts to seal the gasket
Perform complete area housekeeping after work completion.
Clear PTW
HRSG-10 HP Drum Inspection
RA,WMS submission and PTW acquisition.
Open the manhole cover and clean the old gasket from the cover and manhole ring.
Both of the surfaces must be cleaned thoroughly with caution. A method must be
used that does not flatten out the required machined roughness. Gasket surfaces are
to be finished to 125-250 RMS
All manhole covers and rings must be inspected for pits or grooves on the sealing
surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the gasket surface
by weld repair and re-machining. If the manhole covers, rings and plates cannot be
repaired, then they must be replaced
Proper gasket is required to install the cover. Do not flex, twist, bend or deform
the gasket in any way before installation.This could damage the gasket and
compromise its structural integrity
 Center the gasket on the manhole cover. Bring the cover and gasket in contact with
the manhole ring. Install the studs in the plates or yokes and finger tighten to allow
the manhole cover and gasket to stay in place. Make sure the studs, nuts and
washers are clean and well lubricated with nickel anti-seize compound to achieve the
proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when bringing
the cover and gasket in contact with the ring.
To provide an effective seal, even compressive forces must be exerted on the
gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm

You may start to pressurize the boiler at this point. If the gaskets leak, tighten each
nut at a time alternating between the nuts (i.e., use the tightening procedure
described above) until the leaking stops. As the boiler is heated, the internal
pressure will force the cover against the gasket and, if properly installed, the seal will
be effective; however, additional tightening may be required due to the
heating/pressurization. It is to be noted that a "leak", as referenced here, is running
water. A slow drip is acceptable on a cold boiler for this sequence. When the unit is
up to pressure and temperature, if necessary, retighten the bolts to the 290
Nm
If the boiler is shut down and allowed to cool, it is important to again check the
torque on the nuts before re-pressurizing, to assure that the required torque values
have been maintained
Perform complete area housekeeping after work completion.
Clear PTW
U10 IP Drum Inspection
RA,WMS submission and PTW acquisition.
Open the manhole cover and clean the old gasket from the cover and manhole ring.
Both of the surfaces must be cleaned thoroughly with caution. A method must be
used that does not flatten out the required machined roughness. Gasket surfaces are
to be finished to 125-250 RMS
All manhole covers and rings must be inspected for pits or grooves on the sealing
surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the gasket surface
by weld repair and re-machining. If the manhole covers, rings and plates cannot be
repaired, then they must be replaced
Proper gasket is required to install the cover. Do not flex, twist, bend or deform
the gasket in any way before installation.This could damage the gasket and
compromise its structural integrity

Center the gasket on the manhole cover. Bring the cover and gasket in contact with
the manhole ring. Install the studs in the plates or yokes and finger tighten to allow
the manhole cover and gasket to stay in place. Make sure the studs, nuts and
washers are clean and well lubricated with nickel anti-seize compound to achieve the
proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when bringing
the cover and gasket in contact with the ring.
To provide an effective seal, even compressive forces must be exerted on the
gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm
 You may start to pressurize the boiler at this point. If the gaskets leak, tighten each
nut at a time alternating between the nuts (i.e., use the tightening procedure
described above) until the leaking stops. As the boiler is heated, the internal
pressure will force the cover against the gasket and, if properly installed, the seal will
be effective; however, additional tightening may be required due to the
heating/pressurization. It is to be noted that a "leak", as referenced here, is running
water. A slow drip is acceptable on a cold boiler for this sequence. When the unit is
up to pressure and temperature, if necessary, retighten the bolts to the 290
Nm
If the boiler is shut down and allowed to cool, it is important to again check the
torque on the nuts before re-pressurizing, to assure that the required torque values
have been maintained
Perform complete area housekeeping after work completion.
Clear PTW
U10 LP Drum Inspection
RA,WMS submission and PTW acquisition.
Open the manhole cover and clean the old gasket from the cover and manhole ring.
Both of the surfaces must be cleaned thoroughly with caution. A method must be
used that does not flatten out the required machined roughness. Gasket surfaces are
to be finished to 125-250 RMS
All manhole covers and rings must be inspected for pits or grooves on the sealing
surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the gasket surface
by weld repair and re-machining. If the manhole covers, rings and plates cannot be
repaired, then they must be replaced
Proper gasket is required to install the cover. Do not flex, twist, bend or deform
the gasket in any way before installation.This could damage the gasket and
compromise its structural integrity

Center the gasket on the manhole cover. Bring the cover and gasket in contact with
the manhole ring. Install the studs in the plates or yokes and finger tighten to allow
the manhole cover and gasket to stay in place. Make sure the studs, nuts and
washers are clean and well lubricated with nickel anti-seize compound to achieve the
proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when bringing
the cover and gasket in contact with the ring.
To provide an effective seal, even compressive forces must be exerted on the
gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm

You may start to pressurize the boiler at this point. If the gaskets leak, tighten each
nut at a time alternating between the nuts (i.e., use the tightening procedure
described above) until the leaking stops. As the boiler is heated, the internal
pressure will force the cover against the gasket and, if properly installed, the seal will
be effective; however, additional tightening may be required due to the
heating/pressurization. It is to be noted that a "leak", as referenced here, is running
water. A slow drip is acceptable on a cold boiler for this sequence. When the unit is
up to pressure and temperature, if necessary, retighten the bolts to the 290
Nm
If the boiler is shut down and allowed to cool, it is important to again check the
torque on the nuts before re-pressurizing, to assure that the required torque values
have been maintained
Perform complete area housekeeping after work completion.
 Clear PTW
CCCW HX-A Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning

HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
CCCW HX-B Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning

HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
CCCW HX-C Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning

HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 BFP-A manual rotation
U10 BFP B manual rotation
U10 Vacuum pump A manual rotation
U10 Vacuum pump B manual rotation
U10 LP recirculation pump A manual rotation
U10 LP recirculation pump B manual rotation
U10 BFP-A Lube Oil Skid Cleaning
U10 BFP-B Lube Oil Skid Cleaning
U10 ST Hydraulic Skid Cleaning & Silica Inspection
U10 GT Hydraulic Skid Cleaning
U10 Generator Seal Oil Skid Cleaning
U10 Generator Stator Water Skid Cleaning
U10 ST Turning Gear Inspection
U10 GT Turning Gear Inspection
U10 Condenser Rupture Disc Inspection
HRSG-10 PSVs Trevitesting
HRSG-10 PSVs Servicing
HRSG-10 All Manual & Motorized Valves Servicing & Functional Checks
U10 Condenser & Hotwell Inspection
U10 ST Last Stage Blades Inspection
Bladders Nitrogen Pressure Checking
GT & ST Hydraulic Hoses Inspection
Hydraulic Skids Coupling Inspection
Lube Oil Tank Return Strainer Inspection
U10 Water Box Vacuum Pump piping replacement
Gland Condenser Fan Vibration Monitoring
ER OUTAGE JOBS MASTER PLAN
NOVEMBER - DECEMBER 2023

Materail / Spares / Tools / Procedure Lead CP / Lead Planned

QC ChecK Priority
Requirement Engineer Technician Start

Gauge Glass is not available

ISO VG-46 Oil is required

Doubler plate is required (2' x 3')

Welding Machine
Welding Electrode

Manhole gaskets are requied

Shims (0.1 to 0.5 mm)

Dial indicators with fixture
Shim Cutter
Torque wrench (~250 NM)
Hammer (5lb and 10 lb)
General Consumables
65mm sledging wrench
65mm fix spanner
65mm socket wrench
Polythene Sheet
46mm sledging wrench
46mm fix spanner
46mm socket wrench
 65mm fix spanner
65mm socket wrench
Polythene Sheet
46mm sledging wrench
46mm fix spanner
46mm socket wrench

High Pressure Valves (1 Ea)

(DN 25, CL2500)
WPS
Welding Machine
Grinding Discs (4'')
Cutting Discs (4")
General Consumables

Spanner size need to be checked

Teflon Gasket

Gland Packing Specs and availability

need to be checked

OSM tool is required.

Bonnet gasket is required which is
not available
 PR to be created

NRV is not available

Spares of these valves are not

available

Bonnet gasket is required which is

not available

Argon Welding Setup

Bonnet gasket is required which is
not available

Lapping paste is required.

Bonnet gasket is required.

PRV Set Points need to be
communicated to REETS at the time of
PSV dispatch

Insulation Material is not available

Argon Welding Setup

Argon Welding Setup

Gland packing availability need to be
checked

Coupling spider availability need to

check
Overhead crane is not available

Confirm Grease Type and Check

Availability
DE Bearing is not available

Spares of these valves are not

available

Spares of these valves are not

available

Plate Frame HX gaskets are not

available
Gland packing availability need to be
checked

Spares of these valves are not

available

Spares of these valves are not

available

Spares of these valves are not

available
Confirm Grease Type and Check
Availability

Confirm Grease Type and Check

Availability

Plate Frame HX gaskets are not

available
 Plate Frame HX gaskets are not
available

Confirm Grease Type and Check

Availability

Valves & Tubings are not available

Confirm Grease Type and Check

Availability

Valves & Tubings are not available

 Confirm Grease Type and Check
Availability

Valves & Tubings are not available

Confirm Grease Type and Check

Availability

Valves & Tubings are not available

Confirm Grease Type and Check

Availability

Valves & Tubings are not available

Manhole gaskets are required

Hold Point
 PO not issued

Manhole gaskets are required

Hold Point

PO not issued

Manhole gaskets are required

Hold Point

PO not issued

Manhole gaskets are required

Hold Point
 PO not issued

OPS Team must Witness

Hold Point

Manhole gaskets are required

Hold Point
Hold Point Anodes are not available
Hold Point

Gauge Glass is not available

ISO VG-46 Oil is required

Gauge Glass is not available

ISO VG-46 Oil is required

Filters availability need to be checked &
confirmed.

Manhole gaskets are required &

availability is not confirmed

Manhole Gasket is Available

Witness Point

Manhole Gasket is Available

Witness Point
 Manhole Gasket is Available

Witness Point
Record Readings
Special fixture is required for nuts
undoing
Witness Point
KARCHER Machine is available in
store

Gaskets are available in HEI spares

Record Readings
Special fixture is required for nuts
undoing
Witness Point
KARCHER Machine is available in
store

Gaskets are available in HEI spares

Record Readings
Special fixture is required for nuts
undoing
Witness Point
KARCHER Machine is available in
store

Gaskets are available in HEI spares

Planned Actual Actual Completion
Duration
Finish Start Finish Percentage
 UNIT-10 WIN

Notification Work Order

Sr. No. Activity Type
Number Number

1 640001037 4500002481 CM

2 640001006 4400000851 CM

3 640001005 4400000857 CM
4 640000952 4400000890 CM

5 640000945 4400000698 CM

6 640000941 4400000692 CM

7 640000931 4400000681 CM
8 640000813 4400000871 CM

9 640000739 4400000867 CM

10 640000654 4400000866 CM

11 640000131 4400000860 CM

12 640000937 4400000886 CM

13 640000818 4400000626 CM
14 640000546 4400000899 CM

15 640000947 4400000889 CM

16 640000939 4400000887 CM

17 640000819 4400000872 CM

18 640001068 4400000900 CM

19 640001071 4400000832 CM
20 640001063 4400000891 CM

21 640001029 4400000839 CM

22 640001013 4400000771 CM

23 640001012 4400000770 CM

24 640000985 4400000856 CM
25 640000973 4400000842 CM

26 640000966 4400000739 CM

27 640000767 4400000550 CM

28 640001009 CM

29 640001010 CM

30 640001011 CM

31 640000757 4400000551 CM

32 640000546 CM
33 640000545 CM
34 640000483 4400000383 CM
35 640000484 4400000386 CM
36 640000441 4400000394 CM
37 CM
38 CM

39 PM

40 PM
41 PM

42 PM

43 PM

44 PM
45 PM

46 PM

47 PM

48 PM
49 PM

50 PM

51 PM
52 PM

53 PM

54 PM

55 PM
56 PM

57 PM

58 PM
59 PM
60 PM
61 PM

62 PM

63 PM

64 PM
65 PM
66 PM
67 PM
68 PM
69 PM
70 PM
71 PM
72 PM
73 PM
74 PM
75 PM
76 PM
77 PM
78 PM
79 PM
80 PM

81 PM

82 PM
83 PM
84 PM
85 PM
86 PM
87 PM
88 PM
89 PM
 UNIT-10 WINTER OUTAGE JOBS M
NOVEMBER - DECEMBER 2023

Lead CP / Lead
Work Description
Engineer Technician

U10 CEP-A Oil Leakage Rectification

RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEP oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
Record observations after pump has taken into operation.
U10 Debris Filter Lower Half Leakage Rectification
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Debris Filter manways opening.
Debris Filter functional checks.
Debris Filter internal inspection.
Surface preparation for doubler plate welding.
Doubler plate welding.
NDT (DPT) check for weld joint assessment.
Debris Filter manways closing with the presence of OPS team.
Remove temporary arrangements made for leak
Perform complete area housekeeping after work completion.
Clear PTW
U10 BFP-A observed High X Vib of NDE Bearing of motor ~3.2mm/sec
(Alignment Required)
RA,WMS submission and PTW acquisition.
Pump coupling guard removal.
Coupling spacer and shim packs removal.
Measurement of alignment reading.
Pump to motor alignment.
 Motor CCCW connections removal (if required)

Fill alignment protocol after alignment completion

Coupling spacer and shim packs installation.
Pump coupling guard installation.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP bypass v/v upstream vent v/v passing observed
RA,WMS submission and PTW acquisition.
Welding of new high pressure valve in addition to existing vent valves

NDT (DPT) check for weld joint assessment.

Perform complete area housekeeping after work completion.

Clear PTW
U10 CEP B disc flange dropwise leakage
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Flange bolts tightening
Scaffolding removal.
Perform complete area housekeeping after work completion.
Clear PTW
U10 atm tank pump A CCCW inlet reg leak (Seepage observed from
regulator set screw)
RA,WMS submission and PTW acquisition.
Regulator disassembly
Gasket (Teflon) installation
Regulator assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum pump-B (MAJ) Gland leakage
RA,WMS submission and PTW acquisition.
Gland pusher removal.
Gland packing inspection.
Gland packing replacement (if required)
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP CBD leakage from CV side (Leakage is from bonnet)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Valve actuator removal
Valve disassembly (to expose bonnet)
Valve bonnet inspection
Valve bonnet On Site Machining
Valve re-assembly (with new gaskets)
Valve actuator assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 Stator water resin tank flexible pipe
RA,WMS submission and PTW acquisition.
Hose Pipe replacement with new one.
Perform complete area housekeeping after work completion.
Clear PTW
U10 IPB Fan-A NRV Need to check
RA,WMS submission and PTW acquisition.
NRV passing check by keeping Fan-B in operation.
If passing found, duct will be dismantled.
Check for NRV servicing or Install new NRV
Perform duct re-assembly.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP ECO drain iso vlv passing (Valve passing was not checked
because Unit was operational)
RA,WMS submission and PTW acquisition.
Valves cleaning, greasing and servicing.
Valves operational check
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 IP drum PSV leakage observed from bonnet
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
Rigging arrangement to lift PSV.
PSV cleaning and servicing.
Bonnet inspection for steam cuts (if any)
Bonnet gasket replacement.
PSV re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 perf htr IP water support damage
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
 Support welding
Scaffolding removal.
Perform complete area housekeeping after work completion.
Clear PTW
Unit 10 HP saturated steam valve passing
RA,WMS submission and PTW acquisition.
Sampling valve replacement with new one.
NDT (DPT) check for weld joint assessment.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HP drum PSV passing observed (stem observed from PSV drain point
and gland)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
U10 Cond. to LP eco inlet PSV passing (water found dripping)
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Grating cutting for PSV flange bolts removal
PSV disassembly
Plug and seat inspection
Seat lapping (if required)
PSV cleaning and servicing.
Perform complete area housekeeping after work completion.
Clear PTW
U10 Perf htr IP water supply PRV passing
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
PRV disassembly
PRV calibration at REETS Lahore Workshop
PRV re-assembly after calibration
Perform complete area housekeeping after work completion.
Clear PTW
U10 IP CV, Drain Valve Steam Leakage (Steam leakage Observed from
Drain line of U 10 IP Main Control Valve)
RA,WMS submission and PTW acquisition.
Piping insulation removal.
Valve insulation removal.
Lekage point identification.
Leakage rectification.
Piping insulation installation.
Perform complete area housekeeping after work completion.
Clear PTW
U10 HRH drain line leakage near ATM tank
RA,WMS submission and PTW acquisition.
Piping insulation removal.
 Valve insulation removal.
Lekage point identification.
Leakage rectification.
Piping insulation installation.
Perform complete area housekeeping after work completion.
Clear PTW
Gland Leakage frm IP saturated steam v/v
RA,WMS submission and PTW acquisition.
Gland replacement
Perform complete area housekeeping after work completion.
Clear PTW

U10 vacuum pump DE bearing abnormal observed (DE Bearing Greasing)

RA,WMS submission and PTW acquisition.

Review Vibration Analysis report
Coupling guard removal
Pump to motor alignment check
Motor removal
Coupling hub removal
DE bearing grease replacement
DE bearing replacement
Coupling hub re-installation
Pump to motor alignment
Fill alignment protocol after alignment completion
Coupling guard installation
Perform complete area housekeeping after work completion.
Clear PTW
U2 IP startup DRAIN MOV PASSING ISSUE
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U2 HP startup DRAIN MOV PASSING ISSUE
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
Gen-10 Liquid detectr sight glas has oil
RA,WMS submission and PTW acquisition.
Drain Oil present in sight glass
Perform complete area housekeeping after work completion.
 Clear PTW
U10 Vacuum tank temperature high
RA,WMS submission and PTW acquisition.
CCCW HX inspection and cleaning
Perform complete area housekeeping after work completion.
Clear PTW
Salts deposition to be removed in MPB-1
RA,WMS submission and PTW acquisition.
Perfrom skid cleaning
Perform complete area housekeeping after work completion.
Clear PTW
HRSG-10 HP evap drain MOV gland leak
RA,WMS submission and PTW acquisition.
Gland replacement
Perform complete area housekeeping after work completion.
Clear PTW
U-10 IP evap drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U-10 IP startup drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW
U-10 HP startup drain mov passing issue
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Insulation removal for thermography
Insulation installation after thermography
Perform complete area housekeeping after work completion.
Clear PTW

Unit-10 CEP-A self sealing line water flow abnormal sound observed.

Unit 10 Hp saturated steam valve passing

HPS steam line passing Unit 10
HP Drum sampling flushing valve passing
HRSG1 HPSupheated sampling valve Passing
HRSG-10 HP SH Flush V/v is passing
CCCW Pump-B Leakage Rectification & Alignment
 RA,WMS submission and PTW acquisition
Review Vibration Analysis report
Coupling guard removal
Leakages rectification
Pump to motor alignment check
Perfrom alignment
Fill alignment protocol after alignment completion
Coupling guard installation
Perform complete area housekeeping after work completion.
Clear PTW
CCCW Expansion Tank Hose Repair
RA,WMS submission and PTW acquisition
Hose dismantling
Hose repairing (from local market)
Hose re-installation
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump-A NDE Bearing Grease Replacement
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump-A Bearings Grease Replacement
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease (NDE bearing)
Apply new grease on bearing as per OEM recommendation
For DE Bearing
Pump to motor alignment check
Motor removal
Coupling hub removal
DE bearing grease replacement
Coupling hub re-installation
Pump to motor alignment
Fill alignment protocol after alignment completion
Bearing end cover installed
Coupling guards installed
Perform complete area housekeeping after work completion.
Clear PTW
U10 Vacuum Pump CCCW Heat Exchanger-A Cleaning
RA,WMS submission and PTW acquisition.
Disassembly of heat exchanger
Inspection & cleaning of HX plates
Inspection of gaskets
Installation of gaskets
Assembly of heat exchanger
Perfome complete area housekeeping after work
Clear PTW
Leak test will perform
U10 Vacuum Pump CCCW Heat Exchanger-B Cleaning
RA,WMS submission and PTW acquisition.
Disassembly of heat exchanger
Inspection & cleaning of HX plates
Inspection of gaskets
Installation of gaskets
Assembly of heat exchanger
Perfome complete area housekeeping after work
Clear PTW
Leak test will perform
OCW Pump-A Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical
seal flushing lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
OCW Pump-B Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical
seal flushing lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
OCW Pump-C Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical
seal flushing lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
CCCW Pump-A Major Overhauling
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical
seal flushing lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
CCCW Pump-C Bearings Grease Replacement & Cleaning
RA,WMS submission and PTW acquisition.
Remove coupling guards
Remove bearing end cover
Remove old grease
Apply new grease on bearing as per OEM recommendation
Bearing end cover installed
Coupling guards installed
Perfrom complete cleaning of pump body and inspect pump mechanical
seal flushing lines.
Replacement of mechanical seal flushing scheme (if required).
Perfome complete area housekeeping after work
Clear PTW
U10 Debris Filter-A Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Debris filter internal cleaning
Debris filter internal inpection (If found damage report to lead)
 Repair the damage
Debris filter functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Debris Filter-B Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Debris filter internal cleaning
Debris filter internal inpection (If found damage report to lead)
Repair the damage
Debris filter functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Ball Catcher-A Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Ball Catcher internal cleaning
Ball Catcherr internal inpection (If found damage report to lead)
Repair the damage
Ball Catcher functional test
Check gasket , if found good condition.
Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 Ball Catcher-B Internal Inspection & Chemical Coating
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Ball Catcher internal cleaning
Ball Catcherr internal inpection (If found damage report to lead)
Repair the damage
Ball Catcher functional test
Check gasket , if found good condition.
 Application of chemical coating
Box up manways
Perfome complete area housekeeping after work
Clear PTW
GT10 Air Intake (Filter House (MBL) Inspection
RA,WMS submission and PTW acquisition.
Inspection of all filter modules
Inspection of all evap pad modules
Inspection of clean room
Any damage found, repair it.
Filter modules internal cleaning
Perfome complete area housekeeping after work
Clear PTW
U10 Condenser Water boxes Inspection
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access.
Open Manways
Check LEL with Operation team
Water box internal cleaning
Water box internal inpection, if found damage report to lead (hold)
Inspection of anode, if found damage report to lead (hold)
inpection of tubes, If found choked report to lead (hold)
Check gasket, if found good condition.
Box up manways
Perfome complete area housekeeping after work
Clear PTW
U10 CEP Pump-A Oil replacement
RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEO oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
Record observations after pump has taken into operation.
U10 CEP Pump-B Oil replacement
RA,WMS submission and PTW acquisition.
Check for possible points of oil seepage while pump is in operation.
Replace CEO oil level gauge glass with new healthy one.
Perform bearing housing cleaning and housekeeping.
Perform bearing housing end plate bolts tightening.
Fill Fresh ISO VG-46 oil in bearing housing to optimum level.
Perform complete area housekeeping after work completion.
Clear PTW
 Record observations after pump has taken into operation.
U10 Lube Oil Vapour Exhauster Inspection & Filters Replacement
RA,WMS submission and PTW acquisition.
Perform vapour exhauster complete cleaning
Inspect filters condition
Replace filters (air and oil) as per condition
HRSG-10 Inspection
RA,WMS submission and PTW acquisition.
Flue Gas Side
Open all the gas duct manholes. Be sure all local and state safety
practices have been implemented and that the unit is safe for entry and
service
Fill the entire HRSG with water and pressurize to inspect for leaks.
Inspect the interior of the HRSG. At the harps, look for deposits,
erosion, or damage to the fins and tubes
In the gas duct, look for damaged or missing liner casing, clips and
insulation
Check for loose or detached gas passing plates located at the bottom, top,
and side of each module
Look for deposits built up on the tubes, particularly at the cold end of the
HRSG
Units with carbon build-up on the exterior of the finned tubes may be air
blowed or dry ice washed.
Inspect all external surfaces of the HRSG, piping, electrical and
pneumatic service lines and the access platforms for structural integrity
Gas Duct Manhole Usage and Gasketing

Clean the old bolting tape from both surfaces with a wire wheel grinder
Use a bead of silicone RTV or other suitable material to hold new
bolting tape to the boiler casing
Bolting tape shall be a minimum of 3 mm thick and 45 mm wide. The bolting
tape shall lay flat against the surfaces with no laps or gathering of the
material. Teflon impregnated material or semi-liquid coating shall not be
used
Align the door and finger tighten all bolts. Continue tightening bolts to
seal the gasket
Perform complete area housekeeping after work completion.
Clear PTW
HRSG-10 HP Drum Inspection
RA,WMS submission and PTW acquisition.

Open the manhole cover and clean the old gasket from the cover and
manhole ring. Both of the surfaces must be cleaned thoroughly with caution.
A method must be used that does not flatten out the required machined
roughness. Gasket surfaces are to be finished to 125-250 RMS

All manhole covers and rings must be inspected for pits or grooves on the
sealing surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the
gasket surface by weld repair and re-machining. If the manhole covers,
rings and plates cannot be repaired, then they must be replaced
 Proper gasket is required to install the cover. Do not flex, twist, bend or
deform the gasket in any way before installation.This could damage the
gasket and compromise its structural integrity

Center the gasket on the manhole cover. Bring the cover and gasket in
contact with the manhole ring. Install the studs in the plates or yokes and
finger tighten to allow the manhole cover and gasket to stay in place. Make
sure the studs, nuts and washers are clean and well lubricated with nickel
anti-seize compound to achieve the proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when

bringing the cover and gasket in contact with the ring.
To provide an effective seal, even compressive forces must be exerted on
the gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm

You may start to pressurize the boiler at this point. If the gaskets leak,
tighten each nut at a time alternating between the nuts (i.e., use the
tightening procedure described above) until the leaking stops. As the boiler
is heated, the internal pressure will force the cover against the gasket and, if
properly installed, the seal will be effective; however, additional tightening
may be required due to the heating/pressurization. It is to be noted that a
"leak", as referenced here, is running water. A slow drip is acceptable on a
cold boiler for this sequence. When the unit is up to pressure and
temperature, if necessary, retighten the bolts to the 290 Nm

If the boiler is shut down and allowed to cool, it is important to again check
the torque on the nuts before re-pressurizing, to assure that the required
torque values have been maintained
Perform complete area housekeeping after work completion.
Clear PTW
U10 IP Drum Inspection
RA,WMS submission and PTW acquisition.

Open the manhole cover and clean the old gasket from the cover and
manhole ring. Both of the surfaces must be cleaned thoroughly with caution.
A method must be used that does not flatten out the required machined
roughness. Gasket surfaces are to be finished to 125-250 RMS

All manhole covers and rings must be inspected for pits or grooves on the
sealing surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the
gasket surface by weld repair and re-machining. If the manhole covers,
rings and plates cannot be repaired, then they must be replaced
Proper gasket is required to install the cover. Do not flex, twist, bend or
deform the gasket in any way before installation.This could damage the
gasket and compromise its structural integrity

Center the gasket on the manhole cover. Bring the cover and gasket in
contact with the manhole ring. Install the studs in the plates or yokes and
finger tighten to allow the manhole cover and gasket to stay in place. Make
sure the studs, nuts and washers are clean and well lubricated with nickel
anti-seize compound to achieve the proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when

bringing the cover and gasket in contact with the ring.
 To provide an effective seal, even compressive forces must be exerted on
the gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm

You may start to pressurize the boiler at this point. If the gaskets leak,
tighten each nut at a time alternating between the nuts (i.e., use the
tightening procedure described above) until the leaking stops. As the boiler
is heated, the internal pressure will force the cover against the gasket and, if
properly installed, the seal will be effective; however, additional tightening
may be required due to the heating/pressurization. It is to be noted that a
"leak", as referenced here, is running water. A slow drip is acceptable on a
cold boiler for this sequence. When the unit is up to pressure and
temperature, if necessary, retighten the bolts to the 290 Nm

If the boiler is shut down and allowed to cool, it is important to again check
the torque on the nuts before re-pressurizing, to assure that the required
torque values have been maintained
Perform complete area housekeeping after work completion.
Clear PTW
U10 LP Drum Inspection
RA,WMS submission and PTW acquisition.

Open the manhole cover and clean the old gasket from the cover and
manhole ring. Both of the surfaces must be cleaned thoroughly with caution.
A method must be used that does not flatten out the required machined
roughness. Gasket surfaces are to be finished to 125-250 RMS

All manhole covers and rings must be inspected for pits or grooves on the
sealing surfaces
If pits greater than 0.8mm deep exist, it will be necessary to repair the
gasket surface by weld repair and re-machining. If the manhole covers,
rings and plates cannot be repaired, then they must be replaced
Proper gasket is required to install the cover. Do not flex, twist, bend or
deform the gasket in any way before installation.This could damage the
gasket and compromise its structural integrity

Center the gasket on the manhole cover. Bring the cover and gasket in
contact with the manhole ring. Install the studs in the plates or yokes and
finger tighten to allow the manhole cover and gasket to stay in place. Make
sure the studs, nuts and washers are clean and well lubricated with nickel
anti-seize compound to achieve the proper bolt load.

Davits should be adjusted as necessary, to allow the proper alignment when

bringing the cover and gasket in contact with the ring.
To provide an effective seal, even compressive forces must be exerted on
the gasket. To accomplish this, tighten the nuts until the bolting are tight to
approximately the torque values 55 Nm
 You may start to pressurize the boiler at this point. If the gaskets leak,
tighten each nut at a time alternating between the nuts (i.e., use the
tightening procedure described above) until the leaking stops. As the boiler
is heated, the internal pressure will force the cover against the gasket and, if
properly installed, the seal will be effective; however, additional tightening
may be required due to the heating/pressurization. It is to be noted that a
"leak", as referenced here, is running water. A slow drip is acceptable on a
cold boiler for this sequence. When the unit is up to pressure and
temperature, if necessary, retighten the bolts to the 290 Nm

If the boiler is shut down and allowed to cool, it is important to again check
the torque on the nuts before re-pressurizing, to assure that the required
torque values have been maintained
Perform complete area housekeeping after work completion.
Clear PTW
CCCW HX-A Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning
HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
CCCW HX-B Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning
HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
CCCW HX-C Plates Cleaning
RA,WMS submission and PTW acquisition.
Scaffolding erection to build safe access
Measurement of distance between end plates
HX end plates nuts undoing
Plates inspection
Plates cleaning
HX re-assembly
Perform complete area housekeeping after work completion.
Clear PTW
U10 BFP-A manual rotation
U10 BFP B manual rotation
U10 Vacuum pump A manual rotation
U10 Vacuum pump B manual rotation
U10 LP recirculation pump A manual rotation
U10 LP recirculation pump B manual rotation
U10 BFP-A Lube Oil Skid Cleaning
U10 BFP-B Lube Oil Skid Cleaning
U10 ST Hydraulic Skid Cleaning & Silica Inspection
U10 GT Hydraulic Skid Cleaning
U10 Generator Seal Oil Skid Cleaning
U10 Generator Stator Water Skid Cleaning
U10 ST Turning Gear Inspection
U10 GT Turning Gear Inspection
U10 Condenser Rupture Disc Inspection
HRSG-10 PSVs Trevitesting
HRSG-10 PSVs Servicing

HRSG-10 All Manual & Motorized Valves Servicing & Functional Checks
U10 Condenser & Hotwell Inspection
U10 ST Last Stage Blades Inspection
Bladders Nitrogen Pressure Checking
GT & ST Hydraulic Hoses Inspection
Hydraulic Skids Coupling Inspection
Lube Oil Tank Return Strainer Inspection
U10 Water Box Vacuum Pump piping replacement
Gland Condenser Fan Vibration Monitoring
GE JOBS MASTER PLAN
DECEMBER 2023

Fitters Welder Fabricator Insulator Helpers Required Support Description

Scaffolding Material + Scaffolders

Doubler Plate
Welding Accessories + Welder + Fabricator
Electrical Supplies
 Skilled Millwrights (2 Ea) + Helpers (4)
Shims (0.1 to 0.5 mm)
Dial indicators with fixture
Shim Cutter
Torque wrench (~250 NM)
Hammer (5lb and 10 lb)
General Consumables
65mm sledging wrench
65mm fix spanner
65mm socket wrench
Polythene Sheet
46mm sledging wrench
46mm fix spanner
46mm socket wrench

Welding Accessories + Welder + Fabricator

High Pressure Valves (1 Ea)
(DN 25, CL2500)
 Department Duration

BQPS Complex Workshop

BQPS Complex Workshop

BQPS Complex Workshop
BQPS-3 EMD
 BQPS-1 MMD

BQPS Complex Workshop

BQPS-2 MMD