Professional Documents
Culture Documents
SCOPE:
PRESSURE PARTS FAILURE REPORTING, INVESTIGATION, ANALYSIS & DATA SYSTEM AIMS TO ACHIEVE ZERO BTL BASED ON RCA & TIME BOUND CORRECTIVE ACTION PLAN IT DEFINES RESPONSBILITIES OF VARIOUS GROUPS WITHIN THE ORGANIZATION & COORDINATION WITH EXTERNAL AGENCIES TO CARRY OUT DT/NDT INSPECTIONS, INVESTIGATION & ANALYSIS, FEEDBACK & DOCUMENTATION AND ACTION PLAN TO ACHIEVE THE OBJECTIVE BASED ON GENERATED DATA BASE
1. BTL Reporting Format 2. BTL Site Level Investigation Committee : Sampling Methodology: Two photographs 100x150 mm : One in situ, if possible & another after cut Identification plate 300x200 mm painted black with information containing Name of the station, unit no, location 7 details of failure, Date of Failure, Id. No etc Tube shall be cut by saw with 18 either side of failure. If gas cut it must be 24 either side & dressed to 18 by saw later Site Level Investigation: Observations, Analysis, Recommendations & Implementation Plan
3. Reporting at HQ- Operation Services for Further Action 4. Need of Metallurgical Investigation at R&D Lab 5. Documentation, Report Integration & Corrective Action Plan 6. Knowledge Forum for New Technological Adoption 7. Pre-OH predictive scope of work & preparedness 8. Quality Surveillances during unit overhauls (in-house/HQ/External Agency directly under FQA)
BOILER TUBE FAILURE SITE LEVEL INVESTIGATION COMMITTE 1. HOD - Maintenance Management Services: Coordinator 2. HOD- Boiler Maintenance Division 3. HOD- Operations & Energy Efficiency Division 4. HOD- Operations Division
HQ-OS
BTF
R&D Investigations (if required) Observations Corrective Action Plan Monitoring of CAP
QC: External Inspections & NDT
Unit OH Plan
Scope of Work for Unit Overhauls
PREVENTION ASPECTS
OPERATIONAL ASPECTS
LOW PARAMETER OPERATION OF BOILER PRESSURE PARTS (AT LOW PRESSURE & LOW TEMPERATURE) DOES NOT NECESSARIALLY ENSURE LESS PRESSURE PART FAILURES
IMPACT ANALYSIS OF PP-OPERATIONAL REGIME RESTRICTIONS at one of the NTPC-PIE Stations
D-3: Restricted to 95-100 kg/cm2 from design 149 kg/cm2 D-4:Restricted to 120 kg/cm2 from design 149 kg/cm2
UNIT NO
Before (April-Aug 06) Duration= 5 Months Nos MU Lost 63.73 72.79 BTF/M 1.6 0.8 8 4
After (Sept 06-March 07) Duration= 7 Months Nos 10 2 MU Lost 92.42 21.65 BTF/M 1.4 0.3
D-3 D-4
OPERATIONAL ASPECTS
1. NEED OF STANDARD & MANAGEMENT APPROVED OPERATIONAL PRACTICES 2. KNOWLEDGE MANAGEMENT: Forum for discussion &
deliberations
4. MONITOR TEMPERATURE EXCURSIONS: Discuss 5. Ensure availability of all P&I and auto loops/logics.
Avoid drum level surge
during daily review meeting for larger awareness & better control as a good operational practice.
OPERATIONAL ASPECTS
5. ENSURE ADEQUATE/PROPER SOOT BLOWING: Soot Blower operation optimization to prevent erosion due to excessive soot blowing, high steam pressure or pitting due to low /wet steam parameters is essential. There is need to optimize parameter regime as well as frequency of soot blower operation 6. CPU IN SERVICE: to remove all cruds from condensate, to reduce water wall internal deposits 7. CLEAN APH BASKETS: to ensure smooth flue gas flow & reduce second pass deposit & high temperature.
OPERATIONAL ASPECTS
08. COMBUSTION OPTIMIZATION: to reduce slagging & clinker fall, to prevent fin weld fouling, to reduce the need to soot blow, to ensure smooth flue gas velocity, to prevent thermal shocks & vibrations to pressure parts, to prevent implosions/explosions etc combustion optimization is essential. Excess air/ Air ingress control Flue gas temperature optimization 09. TRIP MANAGEMENT: dedicated group for honest trip analysis. Avoid trips
OPERATIONAL ASPECTS
Ownership role of Operations Training & Skill dominant career growth plan
3.
MAINTENACE ASPECTS
5. ADOPTION OF GOOD MAINTENANCE PRACTICES (Contd) Pressurisation of Re-heater circuit/MS Circuit to check for leakage detection Air testing with Sponge ball for testing of loops/coils Develop experiences based schedule for economizer/ Primary SH etc for coil lifting/inspection/reversal Air testing with Sponge ball for testing of loops/coils Inspection of orifice in FSH area to find the cause of overheating Replacement of spacer tube of platen super heater Replacement of DMW, Clamp, shield in primary SH area Phase wise reversal/replacement of ECO coil with new coils instead of total replacement at one time to achieve low down time Thorough & adequate cleaning of pressure parts to ensure effective heat transfer
MAINTENACE ASPECTS
5. ADOPTION OF GOOD MAINTENANCE PRACTICES (Contd.) Restore Supports/ clamps which are cut during work Check Looseness of hanger supports & rectify Check for misalignment of the coils. Replace missing/broken connectors. Ensure all coils are aligned Ensure proper fixing of shields and cassette baffles. Replace all improper shield/baffles Use of latest maintenance tools & techniques eg Portable Bevelling Machine, Plasma Arc Cutting Machine, Portable welding Machine, Headers Hand hole plate cutting machine etc Adequate illumination inside boiler. Use of 24 V supplies & pneumatic tools to prevent loss of life due to electrocution. Use safety nets in S-Panel area. Usage of fibre body hand tools Joint inspection along with safety inspector for scaffolding & planks fix up. Load testing of all T&P
MAINTENACE ASPECTS
6. MISCELLEANOUS AREAS NEED ATTENTION: USE OF PPE & Safety Training to all contract workmen VALVES: All the safety valves are to be serviced and trevi testing done. Actual floating of valves on which maintenance has been carried out should be done. All root valves in the hydraulic test circuit are being serviced and blue matched & witnessed by team of maintenance, operation & quality SOOT BLOWERS: Monitoring of availability of wall blowers & Restoration of LRSB COAL BURNERS: Proper repair hard facing of splitter plates & in side surface/replacement of nozzle etc . Ensure proper alignment of coal/air nozzles.
economizer end erosion use of cassette baffles & refractory for protection
Life Cycle Plan (LCP) Station Rolling Plan (SRP) Station Location Annual Plan (SLAP)
LIFE CYCLE PLAN (LCP)
Focus on major replacement plan for the entire life cycle of 25-30 years. Covers replacement of the equipment/parts which are likely to fail before or near the life expectancy & have a long lead time.
Examples: super heaters, re-heaters, high pressure valves, safety valves, gear reducers, ash disposal lines, slurry pumps, chemical piping, resins, conveyor belts and drives, coal crushers, turbine rotor blades, turbine bolts, boiler feed pump rotor, H.P. heater coil, H.T. motor, transformer, switch gears, cables, etc.
Replacement plans are conceived on the consideration of Coal quality, Creep life of various components, Equipment duty conditions, Actual Wear rate and Behavioral trend of plant /equipment inspection and RLA reports etc.
Years 01 02 04 08
Activity Description Statutory Inspection, Coal Burners, APH Seals. Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil Reversal, DC Batteries Replacement Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Blades, Diaphragm, Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables, Heaters/Condensers/ Heat Exchangers tubes/tube nest etc.
16
25
Unit-2
12-Sep-07 1-Sep-08 29-Sep-07 30-Sep-08 18d 30d Boiler Blr+IP+LP 6.57 6.55
Total
xxx
1 2 3 4 5 6
00 00 00 00 00 00
1/6 to 30/7 10/9 to 30/10
1 to 20/11 1 to 20/2
OBJECTIVES OF UNIT OVERHAUL PLANNING QUALITY FOR RELIABILITY (O2O MAINTENANCE) OPTIMIZE TIME SCHEDULE & COST
Overhaul planning process is initiated with Engineering Declaration 18-24 months in advance. The planning process of any unit outage has essentially three stages: X Pre Shut down Planning activities X Shut down activities X Post shut down activities
Overhaul Execution
Overhaul Monitoring
ENGINEERING DECLARATION
Engineering Declaration of the unit includes brief review of the past performance of the unit, define objectives of the proposed overhaul and the quantified projections of the return in terms of gain in reliability and efficiency.
The first Engineering Declaration is issued 18-24 months ahead of units planed overhaul. Periodic review of outage preparedness facilitates revisions of the plan if any.
DESIGN ASPECTS
1. Reduced flue gas velocity
Erosion=(Velocity)2.6, Preferred Velocity=10m/sec
4. Reduced operating limits of tube metal temperatures 5. Use of suitable material to avoid dissimilar metal welds (DMW) joints
Use of inconel as filler material for root weld reduces failure frequency of austenitic/ ferritic joint , SA 213 T91 avoids use of DMW but making a T91 joint is complex.
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