NTPC Ltd (Corporate Operation services)

Date: 03-12-08

Sub : Report on Sipat - II : For commissioning of unit # 5 The undersigned was on tour from 27/11/08 to 29/11/08 stationed at Sipat STPP to review the unit # 5 commissioning activities . BLU of Unit # 5 has been planed on 12-12-08 to achive full load generation and subsequent activities . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed). 1. LHS milling system 2. PA fan # B , FD fan # B & ID fan # B trial run 3. TDBFP # A & B trial run 4. ESP passes C & D readiness 5. Mill rejects handling system 6. Erection of FG I/L duct for ESP C & D passes 7. ESP C & D pass fly ash handling system 8. Wall blowers and LRSBs commissioning 9. Condensate polishing unit 10. CPU regeneration system 11. Boiler lift Put up for kind persual. Asok kumar Das Sr Manager (OS) AGM(OS)

Annexure NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 30th Nov-08 Milestones achieved 1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08 3. 200 MW achieved on 12.11.08 Target for BLU to achieve 500 MW System /Equipments ready Sl No 1 2 3 4 5 6 7 8 9 10 11 Area Mills Fans APHs ESP pass SADC & burner tilt Safety valves & ERVs Cooling system LPHs Safety valves Ash handling sy CW & CT sy Equipments Mill A- D proven , Mill # E ready for operation FD fan # A , ID fan # A & PA fan # A Pri APH # A , Both Sec APH Pass # A & B Remote operation ready ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C) LPH 1/2/3 BA sy( A,B grinder ) , FA for ESP pass A, B 12th Dec-08

Status of balance system/ Equipments SL NO Equipment LHS mills Mill # F Mill # G Mill # H Mill # J Mill # K Feeders for LHS mill Mill # F Mill # G Mill # H Mill # J Mill # K Coal pipings for LHS mills Mill # F Mill # G Mill # H Mill # J Mill # K Bunkers for LHS mills Mill # F Mill # G Mill # H Mill # J Mill # K Present status 1. Erection completed upto MDV, 2. Rollers / LO piping / Motor alignment / tray works / cabling balance Sole plates erected No erection activity started Erection not started Erection not started Erection not started Erection not started Erection not started 120/ 126 pipes completed 111/122 pipes complted 92/117 pipes complted 73 /114 pipes complted, front required from mill side 71/116 pipes complted, front required from mill side Tar date 5th Dec-08 10th Dec-08 15th Dec-08 20th Dec-08 20th Dec-08 7th Dec-08 10th Dec-08 14th Dec-08 20th Dec-08 20th Dec-08 10th Dec-08 10th Dec-08 10th Dec-08 15th Dec-08 15th Dec-08

Loading clearance given Ready for inspection Ring beams / plan bracings erection in progress 5th Dec-08 SS cone welding in progress in feeder floor 15th Dec-08 SS cone welding in progress at zero meter 20th Dec-08

SL NO

Equipment Fans FD fan # B trial

Present status

Tar date

PA fan # B trial 5 ID fan # B trial

Pri APH # B

1. Motor trial run taken 7th Dec-08 2. LO flushing started on 20/11 & comp by 30/11 3. Blade fixing pending Blade fixing , motor trial , LO lines flushing pending 7th Dec-08 1. Motor alignment in progress , LO pump trial done 2. LO flushing in progress since 27/11 3. 14th Dec-08 Power cabling from VFD Xfmr to SWGR prnding , motor trial 1. LO line flushing , motor trial run , completed 2. Air motor trial run , soot blower & dampers commissioning pending

Balance Ducting LHS PA cold and hot air Duct ready , ATT is to be done duct 15 nos NMEJs to be fixed Balance external ducting (BOF to ESP) O/L duct completed , I/L duct erection in ESP # C pass progress ESP # D pass Pending Insulations PA fan # A Dish duct partially pending FD fan # A Dish duct lower plane pending LHS air duct FD fan # B ESP D pass BFPs TDBFP # A pump trial Cold + hot duct pending Disc duct pending BOF to ESP + ESP + ESP to ID fan Put on barring on 14-11-08 Solo run & pump trial pending LO flusing started on 27/11/08 , compl by 07/12/08 Instrumentation , putting on barring , solo run & pump trial pending ATT done , O/L duct & gates ready Field charging on 05-12-08 ATT done , O/L duct & gates ready Field charging on 20-12-08 Erection completed , dry run and commissioning of remote operation pending

10th Dec-08 20th Dec-08

Insulation material problem

2nd Dec-08

8 TDBFP # B pump trial ESP 9 # C pass # D pass 10 Wall blowers (88 nos) Spray SH spray RH spray 12 13 14 CPU # 5 CPU regeneration Mill reject handling sy

15th Dec-08

11

Remote commissioning done Line erection done / steam blowing done / Flow measurement element to be installed. 1. Vessels erection done , pipings erection in Exp by progress 2. Instrumentation and commissioning 30-12-08 pending PLC commissioning in progress 4 th Dec-08 Pyrite hopper of RHS mills erected

SL NO

Equipment Ash handling sy BA system ECO & APH ash evacuation ESP passes

Present status Grinder A,B ready with disposal line , Grinder C,D installed & to be commissioned , disposal line of grinder C & D erection in progress (Tar 30.11.08) ECO & APH of LHS completed , RHS of APH in progrss ESP A & B pass commissioned Ash evacuation pipings erection in progress Vacuum pump , collecting tower erected Instrumentation ,Commissioning of MHV's,vacuum pump pending 1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending Series A & B ready Water trial completed Motor trial done , pump trial pending Not installed

Tar date

15

#C pass

#D pass Ash handling series Series # A Series # B 16 Boiler lift

Asok Kumar Das SR Manager(OS)

Sipat unit # 5 Turbine bearing temp and vibration Unit # 5 Load 210 MW Load 282 MW Load 500 MW Brg no 1 Axis X Y 2 X Y 3 X Y 4 X Y 5 X Y 6 X Y 7 X Y Brg vibn 19.89 Shaft vibn 86.65 78.84 15.33 117.79 8.35 12.5 16.74 23.05 35.7 38.01 66.28 8.86 24.41 21.87 25.82 30.29 72 74.7 158.04 75.01 88.4 98.7 59.81 88.45 38.64 46.77 76.11 73.03 18.28 76.96 35.34 87.06 63.49 58.07 25.03 56.5 26.3 22.07 36.1 73.4 64 24.6 59 14.2 24.8 67.2 25.4 77 24.5 25 48 71 36.6 50.67 43.9 52.6 77 20.3 20.8 73 35 20.7 33.3 83.9 55.2 88 37.8 49.2 45 58 10.4 18.7 164 25.78 88 26.7 22.8 92 60 13.8 12.9 106 72.5 75 15.5 17.2 151 53 Max brg temp Brg vibn 19.1 Shaft Max brg Brg vibn temp vibn 74.7 79 14.5 11.1 92 73 18.8 Shaft vibn 61

unit # 4 Load 500 MW Max Max brg Brg Shaft brg temp vibn vibn temp 12.6 79 17 8 75 9.8 11 71 14 24 89 27 31 77 56 18 78 17 15 64 19 90 65 97 71 128 58 77 83 78 74 26 80 90 24 33 90 29 80 74 63 72

Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Description Furnace draft Drum level low Drum level high PA header pr

Status of Auto Loop of Sipat # 5 ABB station C&I system Readiness Status from C & I side Yes Yes Yes Yes Normal M/U ready Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Auto Proven in auto Auto Auto Auto Auto Man Proven in auto Proven in auto Auto for HPH 6B/5B Manual Mill A to H Mill A to H Proven in auto Proven in auto Auto Proven in auto Proven in auto Proven in auto

Remarks ID fan kept in manual due to

Hotwell level control D/A level D/A pressure GSC min R/C CEP R/C LPH level HPH level TG/SG ECW DP Mill air flow Mills outlet temp Air flow master Fuel flow master SH spray RH spray Boiler follow mode CMC

HPH 6A/5A not avl

Mill J & K not ready Mill J & K not ready

Put in auto for 1hr 30 mins

BHEL C&I system 1 2 3 4 5 6 7 8

9 10 11 12

Seal steam / Leak steam system Turbine lub oil temp Primary water temp Cold gas temp Control fluid temp HPBH & LPBP Turbine EHC
TDBFP-A seal /Leak steam pr

Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes No

Auto Auto Auto Auto Man Proven in auto Auto Auto Proven in auto Proven in auto Auto Man
MS PRDS not charged

Fuel oil pressure Atomising steam pressure SADC Aux PRDS MS & CRH

NTPC Ltd (Corporate Operation services)

Date 23-12-08

Sub : Report on Sipat - II : For commissioning of unit # 5 The undersigned was on tour from19/12/08 to 22/12/08 stationed at Sipat STPP for unit # 5 commissioning activities .Unit is presently running at 300 MW load with 5 mills (RHS).COD of Unit # 5 has been planed on 31-12-08 . The erection completion and commissioning of the following systems is pending (Detailed list of pending activities has been enclosed). 1. LHS milling system 3. TDBFP # B 4. ESP pass "D" readiness 5. Mill rejects handling system 6. ESP D pass fly ash handling system 7. Wall blowers and LRSBs commissioning
8. Pending insulation of air + FG duct + ESP , FW pipes + HPHs' drips , SH & RH spray lines

8. Ash slurry series A & B 9. Condensate polishing unit 9. Coal tranportation thro' MGR 11. Boiler lift Put up for kind persual. Asok kumar Das Sr Manager (OS) AGM(OS)

NTPC - Sipat stage II (2*500MW) - Status of unit # 5 as on 22 th Dec-08 Milestones achieved 1. Test synchronised with oil on 13.08.08 2. Coal firing on 10.11.08 COD System /Equipments ready Sl No 1 2 3 4 5 6 7 8 9 10 10 11 Area Mills Fans APHs ESP pass SADC & burner tilt Safety valves & ERVs Cooling system LPHs Ash handling sy BFPs CW & CT sy CPU regeneration Equipments Mill A- E proven Both ID fans , FD fans and PA fans (ID fan # B ch -2 not available/VFD xfrm damaged / being shifted from KhSTPP) Both Pri APH , Both Sec APH Pass # A, B ,C Remote operation ready ACW(A/B/C) , SGECW(A/B), TGECW(A/B/C) LPH 1/2/3
BA sy( All 4 grinder ) , FA for ESP pass A, B & C Series # C & D MDBFP & TDBFP A

31st Dec-08

Status of balance system/ Equipments SL NO Equipment LHS mills Mill # F Present status Tar date

1. Mill bearing (lower) damaged during trial run ( After 15 mins running) 2. mill dry run and CAF 26th Dec-08 test pending 1.Mill boxed up ,LO flushing completed. 2.Motor alignment & cabling in progress 3. motor trial exp on 24-12 / mill dry run / CAF test pending

Mill # G 1

25th Dec-08

Mill # H Mill # J Mill # K Feeders for LHS mill Mill # F Mill # G 2 Mill # H Mill # J Mill # K

1. Mill boxed up .Motor trial done. LO flushing in progress 25th Dec-08 3. Mill dry run & CAF pending Erection completed upto MDH Erection completed upto MDH Feeder calibration done Feeder calibration done Feeder / outlet pipe / gate erection done . Feed pipe / bunker outlet gate erection / feeder calibration pending 25th Dec-08 25th Dec-08

25th Dec-08 25th Dec-08 25th Dec-08

SL NO 3

Equipment Coal pipings for LHS mills Bunkers for LHS mills Mill # F Mill # G Mill # H Mill # J Mill # K Balance Ducting PA Duct NMEJs LHS

Present status : Coal pulling done & supports in progress Loading clearance given Loading clearance given on 01-12-08 Loading clearance given on 10-12-09 SS cone erected & welding in progress SS cone erected & welding in progress 13/ 15 nos NMEJs to be fixed

Tar date

25th Dec-08 25th Dec-08

Balance external ducting (BOF to ESP) C pass charged.30 % Insulation pending ESP # C pass 1. 2/2 boxex erected 2. 2nos NMEJ erection , welding of duct /ATT/ ESP # D pass insulation balance Pending Insulations Corners firing zone (high density insulations to Boiler be put) PA fan # A Dish duct partially pending FD fan # A Dish duct lower plane pending LHS air duct Cold + hot duct pending Disc duct pending BOF to ESP + ESP + ESP to ID fan BP + MP (suction & discharge line : partially) Line & spray station Line & spray station FW lines + drip lines Steam blowing of line , LO flusing completed , steam piping / feed water piping in progress Pump alignment , Instrumentation , putting on barring , solo run & pump trial pending To be taken in service after rectification of fields. 30 % insulation pending ATT done , O/L duct & gates ready Field charging / insulation pending Erection completed . Dru run of 46 nos done Put on auto One line each stream ready for manual operation FD fan # B ESP D pass TDBFP # A SH spray RH spray HPHs BFPs

25th Dec-08

Insulation material received / work in progress

TDBFP # B pump trial ESP

30th Dec-08

# C pass # D pass

23-12-08 30-12-08

10 11

Wall blowers (88 nos) Spray SH spray RH spray

12 13 14

CPU # 5 CPU regeneration SWAS

1. Vessels erection done , pipings erection in Exp by progress( resin transfer line , DM water line pending) 2. Instrumentation and commissioning 30-12-08 pending PLC commissioning Pipings in progress / Instrument cabling , Instrumentations and commissioning pending

SL NO 15

Equipment Mill reject handling sy Ash handling sy BA system BA piping

Present status Pyrite hopper of RHS mills erected / for LHS mills pending

Tar date

4 MS lines ready

Clinker grinder & flap gate All 4 commissioned ECO & APH ash evacuation ESP passes Completed ESP A & B pass commissioned Ash evacuation pipings erection in progress(Laterals 250 NB, strainers , pipes of sizes 150 NB, 200 NB , 25 NB urgently required) #C pass 16 Vacuum pump commissioned, collecting tower erected Instrumentation ,Commissioning of MHV's,vacuum pump pending 1. Erection of ash evacution pipings & valves ,collecting tower and Vacuum pump pending 2. Instrumentation ,Commissioning of MHV's,vacuum pump pending Series C & D ready Erection done / Motor & pump trila pending Motor trial done , pump B1 trial done . Trial for PP B2 & B3 pending B line completed ; A > 10 joints pending for rail culverts 27A - Fire has damaged the belt. Belt restoration work to start on 22.12.08. Empty rack run done upto SILO. Delay in awarding in contracts for loading in SILO from Coal India end. Not installed Asok Kumar Das SR Manager(OS)

#D pass Ash handling series Series # A Series # B A/B ADL 17 18 19 LHS tripper MGR Boiler lift

Sipat # 5 Observation prior to full load operation Sl No 1 2 3 4 5 6 7 8 9 10 11 Area 24 meter cable gallery 8.5 meter LPHs + BFP exhaust area Boiler "0" meter Mills area ESP area PA fan area

ESP control room Generator seal oil system Oil station tray Boiler different floor

Full of debris + scrap + construction eqpts Drains not complete + complete drains are full of debris drains around incomplete Drains in front of PA fans incomplte Approach road inbetween PA fans and ESP incomplete Approach to the stair case incomplte Lot of opennings in the control room Full of debris Full of debris Debris + scrap

Sipat # 5 : Activity chart towards full load

Date 17-12-08 18-12-08 19-12-08 19-12-09 19-12-10 20-12-08

Time 15:58 18:41 15:54 16:19

Activity BLU Syn unit triped BLU Syn 15:57 Unit triped

Remarks

"Generator inter turn protection" /Bus duct PT loose

Sipat # 5 : Problems faced in the Journey towards full load Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Equipment CW pp # 4 TDBFP # A ID fan B Ch 2 Mill # F Mill # D Mill # E TDBFP # A Mill # B Sec APH # B Generator bus duct PT UAT # 5B Mill # G Wall blowers PA fan A TDBFP # A Problem faced Triped (first out S1 & S2 energised) Oil lkg from from BP(NDE) return oil line & MP(NDE) RTD VFD Xfrm burnt Bearing damaged during mill trial ( lower brg) Feeder beld damaged , Idler pulley damaged Coal dust lkg from mill top Diaphragm dameged ( Unit triped on Cond vac low) Feeder tripping w/o alarm Rotor stoppage alarm not coming Unit triped on generator interturn protection Syn permissive not coming Vibration high Solution / Action taken P/S module replaced Attended VFD Xfrm being shifted from KhSTPP # 7 Brg replaced Pulley replaced + belt replaced Tightened Diaphragm replaced Fault in the Control supply (Neutral to ground )

PT loose / tightened

Roller setting done

Staem line safety valve flange Gasket replaced with original one gasket leakage (twice) I/O card problem BP suction strainer gasket ruptured Replaced Replaced

MS silica high (35 ppb ) CPU not available