SDSTPS - APPDCL

O&M REVIEW MEETING

ON
07-02-2018
 WELCOME
  TO
2
SRI DAMODARAM SANJEEVAIAH
   THERMAL POWER STATION
   2x800 MW

-03-2017.
FEB-17/Dt.23
18th ORT
 
 
 
 
 
 
 
 
 Achievements during Financial year 2017-18
• New HP line laying work was completed and Unit-1&2 is ready for parallel operation of
bottom ashing.
• Under ground fire hydrant leak was arrested and fire hydrant system is available.
• Unit-1 has completed 4th time continuous running of more than 50 days.
• New LP Water line laying work was completed and Unit-1&2 have independent LP water
line for meeting bottom ash hopper filling, refractory cooling and seal trough filling
• Successfully solved Unit-1 HPT Governing valve-1 hunting problem
• Reduction of DM water consumption from 600 T to 350 T per day after AOH of Unit-1
• Unit-1-HPT- GV-1 hunting problem solved and Unit control is kept on CMC mode.
• Successful completion of Unit-1 continuous running of 30 days (10 th time) after AOH
• Reduction of DM water consumption of Unit-2 from 650 T to 350 T in a day
• Successful completion of Unit-2 continuous running of 30 days (5 th time) after COH works
• Reduction of H2 cylinders consumption after improvement of Hydrogen Purity by
replacement of desicant.
• Unit-2 has achieved continuous running of 66 days (1st time) after completion of Overhaul.
• Successful uploading of AAQMS data of all four AAQMS stations to the APPCB web site.
• Service air line extended to APHs steam line in both Units for carrying out soot blowing
with Air during cold startup condition.
 STATION PERFORMANCE – 2017-18
    Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 TOTAL
  Average Load(MW): 1055 1039 1066 1043 1077 990 849 849 1005 1003
1 Generation (mu) 587.438 572.676 323.955 116.806 485.862 427.666 303.747 245.646 0 453.358 3517.154
2 Monthly %PLF / %Availability 50.99/77.33 48.11/74.08 28.12/42.21 9.81/15.06 40.82/60.66 37.12/60 25.52/48.08 21.32/40.19 0/0 38.08/60.61 29.93/47.73
3 Unit Running Hrs 1113:37 1102:21 607:52 224:02 902:33 863:59 715:30 578:42 00:00 901:56 7010:32
4 Aux. Power Consumption(mu) 41.928 38.26 22.801 14.86 32.425 28.119 26.867 24.08 4.142 30.014 263.498
5 %APC 7.14 6.68 7.04 12.72 6.67 6.575 8.845 9.80 6.62 7.49

6 Washed coal con. (MT) 184541 137251 0 57667 214778 46294 0 89472 0 173552 903555
7 Imported coal con.(MT) 56399 53437 0 10682 30640 0 0 27326 0 27751 206235
8 Total Coal Consumption (MT) 345979 314987 181633 68349 287009 247310 183855 163435 0 290777 2083334
9 Sp. Coal Consumption (kg/kwhr) 0.589 0.550 0.561 0.585 0.591 0.578 0.605 0.665 0.641 0.592

10 LDO consumption (KL) 35.920 18.880 47.000 145 26.755 0 39 74.00 0 77.00 463.555
11 HFO Consumption (KL) 207.000 197.652 125.109 352 228 13.644 182 799.54 0 307.28 2412.217
12 Total Oil Consumption (KL) 242.920 216.532 172.109 497 255 13.644 221 873.54 0 384.28 2875.772
13 Sp. Oil Consumption (ml/kwhr) 0.41 0.38 0.53 4.25 0.52 0.03 0.728 3.556 0.848 0.818

14 DM Water Consumption (M3) 34462 34686 24226 11552 22528 16431 24153 17984 411 18138 204571
15 %DM Make up 1.19 1.21 1.53 1.98 0.96 0.73 1.3 1.2 0.77 1.12
16 No. of interruptions 2 4 2 2 0 1 1 3 0 1 16
17 H2 Cylinders Consumption 81 106 47 32 236 33 34 35 9 77 690
18 Avg. GCV 4373 4449 4350 4322 4251 4225 4185 4074 0 3927 4240
19 Unit Heat Rate 2579 2451 2444 2568 2516 2444 2540 2744 2527 2519

20 Back down Gen. 18.397 187.504 513.816 615.533 103.815 62.243 17.955 44.93 0 119.34 1683.533
760.18/ 837.771/ 732.339/ 489.909/ 321.702/ 290.576/
21 Deemed Gen./EAF% 605.835/ 52.59 63.86 72.72 61.52 589.677/ 49.54 42.53 27.02 25.22 0/0 572.698/ 48.11 5200.687/ 44.26
 Station Performance -2017-18
Station Generation (MU)
587.438 Station- Sp. Coal consumption
572.676
485.862 0.591 0.605 0.665 0.641
0.589 0.561
427.666 453.358
0.585 0.578
323.955 0.550
303.747
245.646
116.806
Station -%APC
0 12.72
8.85
9.80 0.000
7.14
7.04 6.57 6.62
6.68
6.67

0.00

Station-Sp.Oil consumption Station Heat Rate

(ml/kwhr)
2579 2444 2516 2540 2744 2527
4.25
3.56 2451 2568 2444

0.41 0.38
0.73 0.85
0.53 0.52
0.03 0.00
0
 UNIT-1 PERFORMANCE – 2017-18
    Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 TOTAL
  Average Load(MW): 562 514 521 558 532 411 503 520
1 Generation (mu) 402.559 338.592 0.000 116.806 415.420 76.633 0 172.708 0 311.884 1834.602
29.98/58.36
2 Monthly %PLF / %Availability 69.89/99.52 56.89/88.57 19.62/30.11 69.8/100 13.3/20 52.4/83.28 31.23/48.03
3 Unit Running Hrs 716:31 658:58 00:00 224:02 744:00 143:59 00:00 420:10 00:00 619:34 3527:14
15.364 2.119 19.393
4 Aux. Power Consumption(mu) 24.028 20.945 3.511 11.70 22.841 7.793 4.011 131.703
5 %APC 5.97 6.19 10.01 5.50 10.169 8.90 6.22 7.18
6 Washed coal con. (MT) 184541 137251 0 57667 214778 46294 0 89472 0 173552 903555
7 Imported coal con.(MT) 56399 53437 0 10682 30640 0 0 27326 0 27751 206235
8 Total Coal Consumption (MT) 240940 190688 0 68349 245418 46294 0 116798 0 201303 1109790
0.676 0.645 0.605
9 Sp. Coal Consumption (kg/kwhr) 0.599 0.563 0.585 0.591 0.604
10 LDO consumption (KL) 0.000 0.000 0.000 145 0.000 0 39 52.00 0 50.00 286
11 HFO Consumption (KL) 35.000 6.827 0.000 352 5 5.644 0 655.54 0 98.98 1158.99
12 Total Oil Consumption (KL) 35.000 6.827 0.000 497 5 5.644 39 707.54 0 148.98 1444.99
4.097 0.478 0.788
13 Sp. Oil Consumption (ml/kwhr) 0.09 0.02 4.25 0.01 0.07
14 DM Water Consumption (M3) 20703 19194 1243 11525 12958 4248 11139 13223 387 13293 107913
15 %DM Make up 1.11 1.12 1.98 0.67 1.13 1.21 0.83 1.18
16 No. of interruptions 1 1 0 2 0 1 0 2 0 0 7
17 H2 Cylinders Consumption 55 72 0 32 56 15 16 30 6 54 336
18 Avg. GCV 4373 4449 0 4322 4251 4225 0 4074 0 3927 4232
19 Unit Heat Rate 2618 2506 2568 2511 2553 2794 2539 2567
20 Back down Gen. 9.714 121.612 305.184 148.781 74.911 11.322 0 21.743 0 73.824 767.091
412.273/ 460.204/ 305.184/ 265.587/ 490.331/ 87.955/ 385.708/ 2601.693/
21 Deemed Gen./EAF% 71.58 77.32 52.98 44.62 82.38 15.27 0/0 194.451/ 33.76 0/0 64.8 44.28
 UNIT-1 Performance -2017-18
Generation (MU) Sp.Coal consumption (kg/kwhr)
402.559 415.42

338.592 311.884 0.676

0.645
0.599
0.563 0.585 0.591 0.604

172.708
116.806 %APC
76.633

0 0 0 10.01 10.17
8.90
0.000 0.000 0.000
5.97 6.19 6.22 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18
5.50

0.00 0.00 0.00

Sp.Oil consumption (ml/kwhr)

Heat Rate (kcal/kwhr)
4.25 4.10
2794
2618 2568 2553 2539
2506 2511

0.48
0.09 0.02 0.00 0.01 0.07 0.00 0.00
0 0 0
Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18
 UNIT-2 PERFORMANCE – 2017-18
    Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 TOTAL
  Average Load(MW): 466 528 533 444 488 425 460 501 483
1 Generation (mu) 184.879 234.084 323.955 0.000 70.442 351.033 303.747 72.938 0 141.474 1682.552
12.66/22.02
2 Monthly %PLF / %Availability 32.1/55.15 39.33/59.59 56.24/84.43 0 11.84/21.31 60.94/100 51.03/96.17 0 23.77/37.95 28.64/47.43
3 Unit Running Hrs 397:06 443:23 607:52 00:00 158:33 720:00 715:30 158:32 00:00 282:22 3483:18
8.716 2.023 10.621
4 Aux. Power Consumption(mu) 17.9 17.315 19.290 3.16 9.584 20.326 22.856 131.795
5 %APC 9.68 7.40 5.95 13.61 5.790 7.525 11.95 7.51 7.83
6 Washed coal con. (MT) 76624 103255 140502 0 40971 201016 177174 39753 0 76237 855532
7 Imported coal con.(MT) 28415 21044 41131 0 620 0 6681 6884 0 13237 118012
46637 89474
8 Total Coal Consumption (MT) 105039 124299 181633 0 41591 201016 183855 0 973544
0.639 0.632 0.579
9 Sp. Coal Consumption (kg/kwhr) 0.568 0.531 0.561 0.590 0.573 0.605
10 LDO consumption (KL) 35.920 18.880 47.000 0 26.755 0 0 22.00 0 27.00 177.555
11 HFO Consumption (KL) 172.000 190.825 125.109 0 223 8 182 144.00 0 208.29 1253.227
12 Total Oil Consumption (KL) 207.920 209.705 172.109 0 250 8 182 166.00 0 235.29 1430.782
2.276 1.663 0.850
13 Sp. Oil Consumption (ml/kwhr) 1.12 0.90 0.53 3.55 0.02 0.599
14 DM Water Consumption (M3) 13759 15492 22983 27 9570 12183 13014 4761 24 4845 96658
15 %DM Make up 1.33 1.34 1.45 2.32 0.65 0.7 1.16 0.66 1.07
16 No. of interruptions 1 3 2 0 0 0 1 1 0 1 9
17 H2 Cylinders Consumption 26 34 47 0 180 18 18 5 3 23 354
18 Avg. GCV 4373 4449 4350 4322 4251 4225 4185 4074 0 3927 4240
19 Unit Heat Rate 2495 2371 2444 2543 2420 2539 2626 2499 2461
20 Back down Gen. 8.683 65.892 208.632 466.752 28.904 50.921 17.955 23.187 0 45.516 916.442
193.562/ 466.752/ 401.954/ 321.702/ 2598.994/
21 Deemed Gen./EAF% 33.6 299.976/ 50.4 532.587/ 92.46 78.42 99.346/ 16.69 69.78 54.05 96.125/ 16.69 0/0 186.99/ 31.42 44.24
 UNIT-2 Performance -2017-18
Sp.coal consumption kg/kwhr
Generation (MU)
0.605
0.590 0.639 0.632
351.033 0.568
323.955 0.561
303.747 0.573
0.531
234.084
184.879 141.474

70.442 72.938
%APC
0 0
0.000 0.000
13.61 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18
11.95
9.68
7.40 7.52 7.51
5.95 5.79

0.00 0.00

Sp. Oil consumption ml/kwhr Heat Rate kcal/kwhr

3.55 2495 2543 2539 2499
2626
2444
2371 2420
2.28
1.66
1.12
0.90
0.53 0.60
0.00 0.02 0.00
0 0
Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18
 Outage Classification-Fin. Year : 2017-18

 S No Classification of Trip UNIT-1 UNIT-2 TOTAL

1 Boiler & Aux. 3 2 5
2 Turbine & Aux *** *** ***
3 Generator & Aux *** *** ***
4 Off site & Aux *** *** ***
5 C&I System 1 3 4
6 Electrical System *** 1 1
7 Human Error *** *** ***
8 Transmission line & Grid *** *** ***
9 CHP *** *** ***
10 Planned Shutdown (Coal Stock) 2 1 3
11 Reserve Shutdown (No Demand) 1 2 3
12 Miscellaneous *** *** ***
 Total 7 9 16
Boiler Pressure Parts failures in FIN YEAR-2017-18

BOILER PRESSURE PARTS FAILUE

S No.  Area  UNIT-1 UNIT-2 TOTAL
1 ECONOMISER *** *** ***
2 VERTICAL WALL *** *** ***
3 SPIRAL WALL *** *** ***
4 PLSH *** *** ***
5 FSH *** 2 2
6 SH SIDE WALL *** *** ***
7 SH SCREEN TUBES *** *** ***
8 LTRH *** *** ***
9 HTRH 1 *** 1
10 TOTAL 1 2 3
 STATION GENERATION LOSS – 2017-18
Financial Year- 2017 - 2018
  Generation Loss (MU) due to  

Reserve
Unit shut down Start Coal Coal Back
Fin year GEN. T&A B&A P/Q Coal Interuuptio up/Shut feeding Check
Gen. loss Shortage down
ns (MU) down problem Total Loss of
Gen.
Apr-17 587.438 15.417 0 102.149 261.107 0.000 6.622 160.87 0 18.397 564.562 1152.000

May-17 572.676 14.35 7.371 74.569 193.287 104.807 3.857 136.786 0 82.697 617.724 1190.400

Jun-17 323.955 0 0 31.758 279.077 386.629 3.394 0.000 0.000 127.187 828.045 1152.000

Jul-17 116.806 11.047 16.676 13.548 409.0623 602.111 7.728 0 0 13.422 1073.594 1190.400

Aug-17 485.862 18.06 0 82.756 468.36 0.000 5.322 19.753 6.472 103.815 704.538 1190.400

Sep-17 427.666 3.4 0 48.296 0.013 0.000 0.387 609.995 0 62.243 724.334 1152.000

Oct-17 303.747 0 9.863 70.141 22.786 0.000 0 765.908 0 17.955 886.653 1190.400

Nov-17 245.646 0.714 9.329 95.867 240.548 0.000 4.8 510.166 0 44.93 905.640 1152.000

Dec-17 0.000 0 0 0 0.000 0.000 0 1190.400 0 0 1190.400 1190.400

Jan-18 453.358 4.56 3.205 135.857 102.120 0.000 5.227 366.733 0 119.34 732.482 1190.400

                         
TOTAL 3517.154 67.548 46.444 654.941 1976.360 1093.547 37.337 3760.611 6.472 589.986 8227.971 11750.400
                         
Energy% 29.93 0.57 0.40 5.57 16.82 9.31 0.32 32.00 0.06 5.02 70.02 100.00
 COST/Unit Comparison – Fin Year : 2017-18.
Ex-Bus
Coal(MT) Oil(KL)
Cost(Rs.)/Kwhr
Month

Stn.
Gen (MU)
Washed(W Total SPC SOC Coal
Importd(I) LDO HFO Total VC FC TC
) Coal (Kg/Kwh) (ml/Kwh) cost

Apr-17 587 261165 84814 345979 0.589 36 207 243 0.414 5548 3.80 2.48 6.28

May-17 572 240506 74481 314987 0.550 19 198 216 0.378 5502 3.50 2.27 5.77

June-17 324 140502 41131 181633 0.561 40 125 165 0.510 5607 3.67 3.45 7.12

July-17 116.8 57667 10682 68349 0.585 145 352 497 4.25 5362 3.76 2.21 5.97

Aug-17 485.8 245418 41591 287009 0.590 27 228 255 0.52 5316 3.39 2.43 5.82

Sep-17 427.6 247310 0 247310 0.578 0 14 13 0.032 5124 3.19 3.25 6.44

Oct-17 303.7 177174 6681 183855 0.605 39 182 221 0.728 5190 3.50 4.61 8.11

Nov-17 245.6 129225 34210 163435 0.665 74 800 874 3.556 4333 3.34 5.15 8.49

DEC-17 0 0 0 0 NA 0 0 0 NA 0 0 0 0

JAN-18 453.358 249789 40988 290777 0.641 77 295 372 0.82 4355 3.03 2.58 5.61
 FLY Ash Utilisation & Revenue
% Utilisation Fly Ash sales
Month %Ash disposed (SSI, Cement & Revenue Gen.
through HCSD Brick plants) (Rs.)
April-17 32.22 43.95 738793
May-17 36.96 35.73 525139
June-17 7.49 76.32 662328
July-17 0.00 78.51 267919
Aug-17 18.91 56.12 703954
Sept-17 33.57 41.43 267919
Oct-17 4.57 75.43 724506
Nov-17 36.29 38.71 106836
Dec-17 0.00 0.00 0
Jan-18 38.57 36.43 464288
Avg./Tot 26.38 49.86 44,61,682
• LOA is issued for lifting of fly ash 3000 MT per day to M/s. In-Power Cement corporation. Yet to mobilise the
machinery to lift fly ash from silos
• Early action required for extension of ash pond, existing ash pond can have storage volume of 2 months only.
 PLANT ISSUES
• Dredging and desilting of sea water intake system for uninterrupted
water supply to the CW forebay and sea water pumps.
• Coal stock has to be increased .
• Minimum 6 no. vessels in a month to be arranged for running the Units
more than 80% PLF.
• The underground fire hydrant pipe system have many leaks and pipe
lines got eroded, phased manner replacement/rectification is being taken.
• External painting to the Boiler structures, pipe rack columns, tanks are
being taken up in phased manner.
• Extension of Ash Pond and early action on diversion ash bund
 Major Works done in Unit-1 AOH-June-2017
 60 nos. cassette baffles replaced with new in Reheater coils.
 Jet cleaning was done & removed the slagging in pressure parts and PLSH coils.
 D- meter survey was done in pressure parts and refractory was laid in slope areas of all four corners.
 Hot air gate seals were replaced for the mills-B,C & D and damper seals were replaced for all mills.
 Hot air duct leaks were attended and outside insulation was repaired.
 ESP-1B11,1B21,2B21 fields internals were repaired and kept back in operation.
 All mills internal hard facing was done and repair works were done.
 All ESP hoppers thoroughly inspected, cleaned repaired the damaged fields, rapping motors, gear boxes, insulator
switches, rectiformers, fluidising pads and hopper heaters.
 All fly ash lines strengthened, Ash slurry lines were rotated in pipe rack.
 Oil filtration was done 3 nos. GTs and ST-1.
 All HT & LT panels, boards were dust blown, cleaned, terminals tightened.
 All HT/LT panels general maintenance works carried out FD Fan Motor-1B, DMCW Motors Blow down motors overhauls
done.
 All LT Motors and Air compressor motors overhauls done
 All critical pressure transmitters, switches , temperatures probes, flame scanners cleaned and calibrated
 Major Works done in Unit-1 AOH-June-2017
 All MOVs, NRVs CVs cleaned and operation of open/close ensured ALL DCS panels cleaned and terminals tightness
ensured.
 PU Coating done in damaged portions in sea water header, condenser inlet/outlet lines, ACW lines.
 ACW Strainers and PHEs cleaning done.
 CW Pumps cooling coils, Valves and FRP CT inspected and kept cleaned.
 For CWP-1C/1D cleaning of TB cooling coil, overhauling of thrust pads assembly done, for 1C 2/2 assembly inspection and
tighting of bolts carried out.
 HP Turbine GV-1 vale hunting problem rectified.
 CEP-1C pump overhauled condenser and Deaerator cleaning works carried out.
 HP Heaters shell side cleaning done.
 Shroud plates repaired for LP Heaters-1A/2A, 1B/2B.
 Condenser leak test carried out.
 All regular annual shout down works carried out in all divisions.
 S-panel above slope areas in all four corners refractory lining was laid to protect from the erosion of tubes.
 Major Works done in Unit-2-Overhaul : Aug-2017
 The condenser water boxes – 3no. New sacrificial anodes were replaced with the lost one which was found sacrificed
its size during running condition.
 Mill hot air gate and damper seals were replaced and hot air leaks arrested.
 APHs rotor post leaks arrested.
 In ESP-C1-pass inlet gate- deflector plate was placed for uniform distribution of flue gas in C & D passes and
studying the evacuation cycles in C & D passes of ESP hoppers for checking the improvement.
 2 no. ESP fields-1C12 & 1B12 field internals were repaired and kept back in operation
 LP Condenser – cooling water inlet pipe -failed debris screen basket was replaced with new one.
 Turbine inlet steam line – MS temporary strainers were inspected and found debris collection of 5.82 gms, 4.03 gms
in Left & Right side. The collected debris in temporary strainers of ICV1 is 116.70 gms, ICV-2 is 82.99 gms, ICV-3 is
20.76 gms and ICV-4 is 22.07 gms. The values are high side (<14 gms), hence the temporary strainers are kept back
in operation.
 All TG top and bottom bearings were checked and overhauled by M/s. LMTG.
 Major Works done in Unit-2-COH : Aug-2017
 Generator rotor was removed and replaced with repaired one.
 Removed rotor checked thoroughly and properly boxed up, preservation was done.
 Generator stator conductors, core thoroughly checked, leak test was done for the hollow conductors and Teflon
hoses.
 All LT motors and pumps of seal oil & stator water skids were overhauled.
 GTs and UTs – Oil filtration was done.
 CEP-2A,CWP-2A pumps were overhauled.
 Shifting of manhole door from 9 mtrs to 14 mtrs of TDBFPs exhaust duct to facilitate to attend maintenance
works on butterfly valve.
 Bottom ash hoppers refractory repair works were done.
 Condenser CW & ACW pipes inside inspected and damaged areas ‘PU’ coating was applied.
 Plate Heat exchanger-2B (PHE) thoroughly checked and cleaned all elements.
 Major observations in Unit-2 after Overhaul : Aug-2017
 The main turbine shaft vibration of brg.no.-7 is reduced from 24µs(7H) to 21µs(7H).
 The main turbine bearing vibration of brg. No.-4 is reduced from 22 µs (4H) to 17 µs(4H).
 Generator Hydrogen purity is maintaining more than 98.5% after replacement of Desicant in Hydrogen drier & seal ring overhaul.
Make up cylinders are virtually nil and purging cylinders consumption has reduced to one cylinder in a day.
 The super heater DESH spray flow(R) is raised from 44 tph to 95 tph after removal of obstruction in the spray line by cutting the
pipe line at DESH spray attemperator.
 The air preheater flue gas ∆p is reduced from 190 mmwcl to 130 mmwcl after water washing.
 PAFan-2B vibration has reduced after fan overhaul and rectified the blade looseness problem and removed the fallen retaining ring
inside the fan blade bullet assembly.
 ESP-1C12, 1B12 fields are restored after rectification of the field internals.
 The clinker grinders vent pipe line modification was done and there is no venting of ash from the vent pipe.
 Mills seal air ∆p is improved after arresting seal air fan leaks at the fan discharge.
 Boiler 2nd pass ring header passing drain valves are overhauled, Separator passing safety valves overhauled and thereby Boiler
hydraulic test was done smoothly up to 325 bar successfully.
 4 no. of ESP hoppers were identified (A41, B31, B41, C11) (much coarse ash collected hoppers) and being provided wet system for
clearing coarse ash.
 BOILER DIVISION
 Unit-2- Boiler main steam stop (MS-2) valve broken stem was replaced with new one.
 In Unit-2 –ESP-2B12 field was restored after rectification of the field internals during unit shut down.
21
 Interconnection line with isolation valve is provided between CHP dust suppression discharge line and service water
discharge line headers for strengthening the seal water system.
 In Unit-2- ESP-1B12 & 2B12 fields were repaired and kept back in operation.
 ETP- common collection sump was cleaned.
 Unit-2 APHs rotor post air leaks were arrested.
 Unit-2-Mill inerting system was checked and operated steam to Mill-2F system.
 Unit-1-Feeder-1F damaged feeder belt was replaced with new one.
 Unit-2 BA hopper feed gate-2B seal kit was replaced.
 Gravemetric feeder-1E belt was replaced with new one and calibration of the belt was done.
 Boiler Reheater tube leakage was attended.
 In Unit-1 -Boiler seal plate at rear side was repaired and additional plate was welded with the existing one to provide
sufficient clearances after BA hopper-2B steam Pressurisation occurred on 10-07-2017 at 13:50 hrs.
 Unit-1 – Hydraulic seal trough was repaired and ensured sufficient clearances for boiler expansions.
 Mills -1B,1C & 1D for ring rolls adjustment were carried out.
 ESP-2D11 & 2D21 under voltage fields were rectified.
 Ash slurry disposal pumps series-2 suction pipe line obstruction was removed and slurry sump was cleaned.
 BOILER DIVISION

 In Unit-1 AC scanner fan impeller was replaced with new one. 22

 In Unit-2- PAFan-2A discharge side failed expansion bellow was replaced.
 In Unit-1 Separator safety valves A1 & B2 were done overhaul.
 Unit-1 Boiler hydraulic test was done up to 290 bar after attending separator safety valves passing and found no leaks.
 PAFan-1A & 1B internal inspection & Overhaul was done. Replaced all the blades of PAFan-1A, Hydraulic Adjustment Device
overhauled and all the blades of PAFan-1B made free by removing saltation deposits under the supervision of M/s. BHEL-Ranipet .
 Some of the passing valves were replaced with new one in FOPH- PRDS line.
 PAF-1A discharge failed expansion bellow was repaired.
 Gravimetric feeder-1D & 1F – failed feeder belts were replaced with new one.
 In Unit-2 MEFC valve was overhaul done and noticed lot of debris in the valve cage.
 Coarse ash slurry pump was overhauled (Unit-2).
 Unit-1 Boiler rear arch ash cleared.
 Unit-1-Extention of plat form at mill bay – 4.5mts was done.
 Ash water sump was cleaned.
 For both APHs in Units-1&2 alternative service air line is provided for soot blowing during cold startups.
 AHP DIVISION
• In Unit-1-ESP-Buffer hopper-1A bag filters were replaced with new one.
23
• The laying of new HP line work is completed and the units can have a provision of carrying out parallel
bottom ashing.
 Silo-1 Scavenger fan was replaced with new one with higher capacity.
 Unit-2- Vacuum pumps- seal water supply is extended from service water O/H line.
 Ash slurry disposal line -2- pipe line was replaced with new one at road crossing near fire station area.
 Transport Air Compressors-1,2 & 3 servicing was done by the service person.
 Ash slurry disposal line-1 leak at underground near fire station arrested and replaced MS pipe with cast basalt pipe
( nearly 6 mts.)
 Silo-1 mixing tank external surface was painted with coating.
 Laying of additional LP water line was completed.
 The new LP line laying work was completed and kept in service, found normal.
 In AHP- Vacuum pump-9 was replaced with new one.
 In AHP TAC-3 & 5 compressors servicing was done.
 TAC-5 Preventive maintenance works carried by service engineer.
 Unit-1 buffer hopper bag filters maintenance work done.
 EM1 DIVISION

 ST-1 bay equipments were carried out cold line washing with high pressure jet cleaning with DM water.
 Manubolu-I&II – 400 KV lines – insulators at loc-20 to 40 replaced with SRC by APTransco after repeated tripping of line
faults on tracking and all bay equipments were cleaned with cold line washing.
 Diesel Generator-1 failed battery was replaced with new one.
 Unit-2-FDF-2A failed motor terminal box was replaced with new one.
 Chittore-2- 400 KV line dia. stacks and insulators were cleaned with high pressure jet cleaning with DM water.
 Unit-1-Feeder-1B drive motor was replaced with new one.
 CWP-1D motor cooling heat exchanger cooler was cleaned.
 400 KV- Bus-II insulators were cleaned with high pressure jet DM water – cold line washing was done.
 UAT-1A & 1B transformers – Oil filtration works were carried out.
 400 KV- Manubolu- line-1&2 Chittore-Line-1&2 circuits auto reclosing relay protection schemes were checked.
 Unit-2 Generator exciter – 30 no. brushes were replaced with new one.
 SAT-1,UAT-2A,UAT-2B,CHP Aux. Tr-1 & 2 – Transformer oil filtration was carried out.
 Erection of spare CT in BR-2 Dia. was done.
 DMCW-2C motor was checked for alignment and reduced the coupling end vibrations.
 ACWP-1A motor NDE end side bearing was replaced with new one.
 EM1 DIVISION

 ACWP-1A NDE side bearing replaced with new one. 25

 UAT-2B , ST-I & II Oil filtration was done.
 Replacement of 407 Bay B-Phase CT with BR-2 Dia. CT due to oil leak.
 USS-1A & 1B cables are inter changed to facilitate easy maintenance.
 400KV Manubolu-1 – 409 CB – breaker pad clamps were replaced.
 General maintenance works carried to HT&LT boards of BCA, BCB, SSS4 & WTP-MCC CW-MCC and ECP-MCC.
 General maintenance works carried for dry type transformers of SST-1A,3A,4B & UST-1A&B.
 Commissioning of OMICRON Relay test kit completed. Testing of GT-2 Relays carried out.
 ACWP-2A & 2C motors were overhauled.
 In 400 KV switch yard- Bus-2 isolators maintenance & alignment works were done.
 TM DIVISION
 Unit-2-MDBFP motor DE & NDE side bearings, booster pump DE & NDE side bearings, booster pump coupling were replaced with new
26
one, motor and hydraulic coupling alignment was done in presence of M/s. Teco service person. Earlier MDBFP got tripped on motor DE
side bearing temperature high protection.
 Unit-1-HPH-8B water box safety relief valve replaced with new one.
 Unit-2-HPH-6A&6B man hole door leaks were arrested.
 Unit-1-Stator water system make water line safety valve leak was arrested and provided isolation valve in that line.
 In Unit-1-TDBFP-1B gear box low speed shaft vibration problem was solved after inspection of gear box and alignment of the system.
 Unit-1- MDBFP- suction valve passing was arrested.
 In Unit-1 – 1no. Condenser tube leak identified, failed rubber dummy was replaced with titanium dummy and seal welding was done and
condenser fill test was done.
 In Unit-2 HPHs shell side was cleaned with condensate water after CPU, to remove dissolve the chloride deposits if any,
during unit long shut down period.
 Unit-1- LP Shell condenser – A-1 no. tube & -LP shell cond.-B-3 no. tubes were plugged and these tubes were identified by carried out
Fluorescent Dye leak test with UV lamp method by M/s. Arudra.
 TDBFP-1B exhaust end man hole door was replaced from 4 Mtrs to 9 Mtrs. near to exhaust butterfly valve end.
 TDBFPs-1A&1B drain tank vent line a isolation valve provided for easy operation.
 In Unit-1 Isolation valve is provided at Deaerator overflow line to avoid hammering during overflow period.
 Unit-1 Oxygen dozing skids were checked and made ready for OT mode.
 CAM DIVISION


27 were
In WTP, RO-II –B-skids membranes were replaced with new one, and also RO-1-Skid-C-membranes
replaced with new one.
 In Unit-1- CWP-1C thrust bearing temperature high problem was resolved by carrying out flushing of the
suction lines.
 Fire hydrant system – underground pipe line leak at CHP area was arrested and fire hydrant pumps are
operating continuously and even fire water tank level is maintaining.
 CWP-1C thrust bearing cooling water lines were flushed and repeated complaint of temperature rise problem solved.
 ETP-floculator gear box hub was repaired and kept back into operation.
 Air compressors routine and preventive maintenance works were done by the service person.
 FRP cooling tower sump was cleaned during both Units shut down period.
 Air compressor- air drier-1 – failed 3 way valve was replaced with new one.
 Air ingress into the DMCW system suction pipe lines were resolved after identifying leaks at service air after cooler &
Instrument drier-1 tower-A heat exchanger.
 Sea water pumps discharge pipe lines failed ‘PU’ coating repair work was done.
 CAM DIVISION

 RO reject water pump discharge line –GRP leaks were attended. 28

 In WTP filter feed line discharge line leaks were attended.
 In WTP-RO1-C-skid Vitalic coupling and 2 no. membranes were replaced.
 In WTP – GRP flange leakage was rectified by replacement of spool piece.
 Instrument air drier1 bottom - 4 way valve was replaced with spare one.
 Hydrant water leaks were arrested at 400 KV switch yard area.
 Instrument air drier-1- 4 way valve (bottom one) replaced with new one.
 In Switch yard - Compressor of AC system was done overhaul.
 In Sea water pump house- Thrust bearing cooling water system pump-2 was replaced with new one.
 Instrument air drier-No.3 - four way valve replaced.
 In Unit-2 condenser pipe lines external painting (Juton) was done.
 Sea water underground line leakage- CT blow down to Ash water make up line - leakage was rectified.
 C&I DIVISION


29 were
In WTP, RO-II –B-skids membranes were replaced with new one, and also RO-1-Skid-C-membranes
replaced with new one.
 AAQMS- Station instruments were calibrated and kept under observation.
 HIREL service engineer came and attended charger complaints
 Unit-2 gravimetric feeder-2D & 2E were calibrated.
 In Ash pump house- PLC system –failed UPS-A –stream supply was restored.
 Unit-2 side process control loops were tuned for load ramp up & down with 10 MW/min by the M/s. Emerson
Engineer.
 In CHP coal conveyors-BCN-5&7, Stacker-1&2, 9A&9B belt weighers were calibrated
 In Unit-2 Dynavane filter and control valve was commissioned and kept in operation.
 All AAQMS stations analysers were calibrated and uploading of data to AP Pollution web site was done successfully.
 In AHP- PLC – UPS- B stream failed and repaired at site by replacing 2 no capacitors.
 In AHP – failed UPS-2 was rectified by replacing capacitor and power contactors.
 APH-2A inlet flue gas damper actuator was replaced with repaired one.
 CHP DIVISION

 External pipe conveyor-A&B stream belt got twisted and kept back to its normal position and kept30
back for
operation.
 In CHP- ERH-2- BCN-7 fire got erupted and damaged belt cable of around 150 mts.,control cables, power
cables were replaced with new one and ERH-2 available for operation.
 BCN-7A & 2A belt joint work and BCN-9B HS coupling replacement works were done.
 Stacker-1 boom conveyor take off pulley bearings were replaced with new one.
 Stacker-2 boom conveyor drive pulley bearings were replaced with new one.
 Stacker-1 boom conveyor gear box oil seals replacement was done.
 In CHP – conveyor belt-8A repair work was done.
 In CHP- coal conveyor-8B belt joint work was done.
 In CHP- Pipe conveyor-101B, BCN-3 belt joint work was carried out.
 Stacker-I –balancing and painting works carried out.
 Stacker-1 boom conveyor gear box oil seals replaced.
 Conveyor -1B failed belt joint repaired.
 EM2-Major Works done

 External coal conveyor – VFD problem was resolved by replacement of inverter phase module.31
 Paddle feeder motor of silo -1 overhaul was done.
 ESP –Unit-2- AC plant AHU motor bearing replaced with new one.
 CIVIL

 Ash slurry disposal line-1, HCSD dis. line-1&2 damaged pipe lines were repaired.
 Ash water recovery pump discharge line was repaired at different arears of the line.
 Ash water recovery pump discharge lines – GRP leaks were attended.
 Sea water pump thrust bearing cooling system, cooling water tank was cleaned.
 WTP-Raw water sump was thoroughly cleaned and lot of accumulated sand & debris were
removed.
 CW pumps suction chamber screens were cleaned.
  
THANK YOU 33
  
ONE & ALL
  

-03-2017.
FEB-17/Dt.23
18th ORT