PRESENTATION ON (site name)

C&I MAINTENANCE 2014-15

presented by
(S.VAIRAMUTHU)

HODs MEET 2015

AP-TG REGION

VENUE: CHENNAI
DATE:

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

INTRODUCTION
Plant capacity and type

Boiler : CFBC, 2*130TPH , GB

ENMAS.
Turbine: 3 Extraction ,2*35MW,
Siemens
Type
: CPP
Plant :Gummudipondi.
Plant commissioned on :12.06.2013
Plant O&M commenced on : MACH
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

SIGNALS ARCHITECTURE

FIELD
INSTRUMEN
TS

JUNCTIO
NBOX

MARSHALLI
NG
CABINET

SYSTEM
CABINET

NETWORK
STATION

OPERATING
STATION
ENGG
STATION

10/24/16

SEQUAN
CE
EVENT
STATION
MANKIND IS IN PURSUIT OF TRUTH,
LET US WORK TOWARDS THIS

PRINTING
SERVER

ETHERNET SIGNALS
CONNECTIIVITY
SEVER -1

CONTROLLER- 1

CONTROLLER- 2

ETHERNET
SWITCH -1
OS- 4

CONTROLLER- 3
OS- 5

OS- 1

ETHERNET
SWITCH -2

OS- 6

OS -2

OS-3

OS- 7

PRINTINTER

ASPECT SERVER- 1

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

:
DATE : to
2 show
DATE :in
3 this
DATE
: 4
DATE : 5
DATE
If not
able
slide,
may
1
show inBFPseparate
sheetL.P. DOSING J-SEAL BLOWER
HOTWELL
#1
H.P DOSING
PUMP-1

BC # 1A

GUARD
PUMP-1
RO
CLEANING
PUMP #1

PUMP # 1
SERVICE
SERVICE AIR
WATER PUMP COMPRESSOR
#1
-1
BURNER
SYSTEMS
(INST)

DE FAN & RAV

#4

PUMP # 1

#1

OVE FAN #1

GSVC FAN # 1

MB
BLOWER # 2

DCS COSOLE
PANEL(INST)

BC # 2
SOX & NOX
SYSTEM (INST)

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

:
DATE
DATE : in
8 this
DATEslide,
: 9
DATE :
DATE
If not
able: 7to show
may
6
10
in separate sheet
ALL show
SOOT
BLOWERS1

ACW PUMP # AUX. CT FAN INST. AIR COMP CT MAKE UP

1
#1
#1
PUMP # 1

ESP
DENSPHASE
VESSEL #
(1-5)

CEP # 1

SWAS SYSTEM
PRIMARY
INSTRUNENTS
SCREEN # 1A

10/24/16

AIR DRYER # 1

RO HIGH
PRESSURE
PUMP # 1

MGF FEED
PUMP # 1

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

: 11 able
DATE : to
12 show
DATEin
: thisDATE
:
DATE :
DATE
If not
slide,
may
13
14
15
show in separate sheet

SERVICE WATER
PUMP # 2

SAC FEED
PUMP # 1

H.P DOSING FINS CLEANING ACC FAN #(1PUMP # 2

PUMP # 1
8)

DM TRANSFER
PUMP # 1

SLUDGE
TRANSFER
PUMP-1

SERVICE AIR
NEUTRALIZING UF BACKWASH
COMPRESSOR
PIT PUMP # 1
PUMP # 1
-2

DEGASSER
BC-1A VIBRO
BLOWER # 1 FEEDER # 1,2

UF FAST
FLUSHING
PUMP # 1

HRSCC FEED
PUMP#1

DE FAN &
RAV # 2

SECONDARY
SCREEN # 1

BC # 3

SWAS SYSTEM
(INST)
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

: 16 able
DATE :to
17show
DATE
: thisDATE
: 19 may
DATE :
DATE
If not
in
slide,
18
20
show in INITIAL
separate
sheet L.P. DOSING
FLUDISING
J-SEAL
BFP # 2

HOTWELL
PUMP # 2

FILLING
PUMP-1

BLOWER (1-3)

PUMP # 2

BLOWER # 2

CT FAN-2

FLY ASH
CONDITIONER
(1-3)

OVE FAN #2

GSVC FAN #
2

FLY ASH
INST. AIR
ACW PUMP #
OIL
CONDITIONER( COMPRESSOR
2
CENTRIFUGE
1-3)
#2
BC-1B VIBRO
OBMS - A & B
FEEDER # 3,4
APH
SYSTEM-1,2
(INST)
10/24/16

AIR DRYER-2

RO HIGH
PRESSURE
PUMP # 2

SECONDARY
SCREEN # 2

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

: 21 able
DATE :to
22show
DATE
: thisDATE
: 24 may
DATE :
DATE
If not
in
slide,
23
25
show in separate
sheet
SERVICE WATER SAC FEED
H.P DOSING LDO LOADING CT MAKE UP
PUMP # 3

PUMP-2

PUMP # 3

PUMP # 1,2

PUMP # 2

CEP # 2

MGF FEED
PUMP # 2

GUARD PUMP2

LDO
UNLOADING
PUMP # 1,2

DEGASSER
BLOWER # 2

BORE WELL
DCF 304 ,
BC # 4 WITH
CRUSHER
#
1
MB
BLOWER-2
SUMP
305
TIPPER TRALLEY
PUMP 1, 2,3
DM PLANT
SOX & NOX
VALVES,
SYSTEM (INST)
TRANSMITTER

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PM SCHEDULE -2014 -2015

: 26 able
DATE to
: 27show
DATE
: thisDATE
: 29 may
DATE :
DATE
If not
in
slide,
28
30
show in JOP
separate
sheetINST AIR COMP SAC FEED
#1,2
DM TRANSFER
PUMP # 2

PRESSURE
GAUGE

CT FAN-3

SLUDGE
TRANSFER-2
PRESSURE
GAUGE

SERVICE AIR
COMPRESSOR
-3

UF FAST
FLUSHING
PUMP # 2

CRUSHER # 2

MOP & AOP

PRESSURE
GAUGE

BELT WEIGH
SYSTEM(INST)

10/24/16

#3

PUMP # 3

MGF FEED
PUMP # 3

RO HIGH
PRESSURE
PUMP # 3

HRSCC FEED UF BACKWASH

PUMP#2
PUMP # 2
GAUGE
GAUGE
N PIT PUMP #
2
PH & GAUGES

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

ACW
PUMP # 3
GAUGE

10

C&I MAINTENANCE ACTIVITIES

10/24/16

MONTH

PM-PLAN

PMACTUAL

CBM

BDM

APR14

NIL

NIL

35

NIL

MAY14

NIL

NIL

33

JUNE14

NIL

NIL

35

NIL

JULY14

45

15

32

NIL

AUG14

45

18

28

NIL

SEP14

45

15

36

OCT14

45

24

30

NIL

NOV14

45

28

35

DEC14

45

35

38

JAN15

45

18

16

29

FEB15

45

28

30

NIL

MAR15

45

32

13

11

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

11

NO. OF TRIPS/OUTAGES DUE TO C&I

EQUIPMENT FAILURES
MONTH

TRIP
DESCRIPTION

DURA
TION

REASON FOR TRIP

REMEDIAL ACTION
TOOK

APR14
(4
Trips)

NIL

NIL

NIL

NIL

1.
BOILER &
TURBINE GOT
TRIP.

3.35
hrs

MAY14
(3
Trips)

JUN14
(0 Trip)
10/24/16

2.
BOILER &
TURBINE GOT
TRIP.

PA-2 TRIPPED DUE

TO MOTOR DE
TEMPERATURE HIGH

UPS-1 & 2 FAILED

18.30
.SO DCS SYSTEM
hrs POWER FAILED AND
PLANT TRIPPED

3. BOILER &
TURBINE GOT
TRIP.

2.45
Hrs

UPS - 1 & 2
SYNCHRONISED

NIL

NIL

NIL

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

RTD TERMINATION
TIGHTNESS WAS
CHECKED
SMPS CARD
REPLACED
UPS - 2
CHECKED
NIL
12

NO. OF TRIPS/OUTAGES DUE TO C&I

EQUIPMENT FAILURES
MONTH

JULY14
(1Trips)

TRIP
DESCRIPTION

1. BOILER &
TURBINE GOT
TRIP.

DURA
TION

REASON FOR TRIP

TURBINE SHAFT
VIBRATION
19Hrs

HIGH(FRONT
JOURNAL BEARING)
NIL
NIL

REMEDIAL ACTION
TOOK

AUG14 (0
Trips)

NIL

SEP14 (O
Trips)

NIL

NIL

NIL

NIL

OCT 14 (0
Trip)

NIL

NIL

NIL

NIL

NOV 14 (0
Trip)

NIL

NIL

NIL

NIL

DEC 14 (0
Trip)

NIL

NIL

NIL

NIL

JAN 15 (0
Trip)

NIL

NIL

NIL

NIL

10/24/16
FEB
15 (1
Trip)

IN PURSUIT
OF TRUTH,
BOILER
TRIPPED
1. BOILERMANKIND
&LET US IS
WORK TOWARDS THIS
DUE TO LOOP SEAL
TURBINE GOT

NIL

13

RTD termination

MAJOR C&I MAINTENANCE ACTIVITIES

MONTH

ACTIVITIES

1. SA to Furnace
Damper
HV-1092
2. Oil level switch removed
APR14 then, inserting tube hole dia
was increased then reaffixed.
3. Loader -2 calibration
work done
1. UPS- 1 & 2 SMPS &
MAY14 IGBT card was failure,
so replaced
JUNE
14

10/24/16

Service air
compressor -1 Oil
separator, OIL -60
litters was replaced

DURATION
(date & time)

REMARKS

4 hrs

Positioner was
calibrated due to
moisture in air line

4 hrs

Float guard hole was

increased .

4 hrs

Loader -2 cross
checked to Weigh
bridge

18.30 hrs

SMPS, IGBT Card was

replaced

8 hrs

Running hours was

reached above 4000
hrs

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

14

MONTH

MAJOR C&I MAINTENANCE

ACTIVITIES
ACTIVITIES
DURATION
REMARKS
(date & time)

1. DeaeratorBleed
steam control valve
packing inner dia was
reduced 2 mm after
taken on line
JULY14
2.UPS - 2 card alarm
was came
3. Service air compressor
-1Loading and Un loading
cylinder to be serviced
1. Dryer 1 tower- 1
AUG14 & 2 valve inspection
work done
SEP14 1. ID fan -1
Temperature scanner
power card replaced

10/24/16

8 hrs

Valve strauckup
problem

4 hrs

Service Engg was

reset the alarm

4 hrs
5.30 hrs

3 hrs

1.Boiler Bottom bed

16 hrs
thermo well
MANKIND IS IN PURSUIT OF TRUTH,
modification work
LET US WORK TOWARDS THIS
done

Power card failure

Normal
15

MONTH

MAJOR C&I MAINTENANCE

ACTIVITIES
ACTIVITIES
DURATION
REMARKS
(date &
time)

Loop seal blower

8 hrs
LOOP TEST
bearing temperature
element was cross
checked with DCS
SOX, NOX analyser
8 hrs
OCT1
Sox, NOX sensor
4
was checked and
calibratated with
standard gas
Oxygen analyser
4 hrs
cross checked with
standard gas 8.1,4 %
Air Dryer -2 inlet ,
7 hrs
NOV1
out let and Drain NRV
4
service work done
IAC - 3 new
DEC1
3 hrs
TEMPERATURE
temperature switch
4
SWITCH
was replaced and
MANKIND IS IN PURSUIT OF TRUTH,
taken on line
10/24/16
LET US WORK TOWARDS THIS

16

MONTH

MAJOR C&I MAINTENANCE

ACTIVITIES
ACTIVITIES
DURATION
REMARKS
(date &
time)

Loading and
unloading power
cylinder connecting
rod was replaced for
IAC -2 after trail
DEC1
taken on line
4
SOX , NOX sample
inlet SOV was
replaced
CHP - A stream inter
lock was checked
UPS -1 IGBT card
was replaced and
JAN taken on line, UPS - 2
15
was checked
Swas sample cooler
cleaning work done
10/24/16

5 hrs

CONNECTING PIN

5 hrs

SOV 01 NO

6 hrs
UPS -1 IGBT 01
NO
5 hrs

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

17

MONTH

MAJOR C&I MAINTENANCE

ACTIVITIES
ACTIVITIES
DURATION
REMARKS
(date &
time)

HP heater Level
5 hrs
transmitter impulse
line was modified
Cep recirculation
5 hrs
Flow transmitter
impulse line was
modified
ACC fan - 8 vibration
3 hrs
Vibration Switch 01
switch sensor
JAN15 sensitivity problem,
so replaced new
one.
AIR dryer- 1 & 2 By
8hrs
pass Isolation valve
was modified
Boiler main steam
2hrs
stop valve limit
switch adjustment
MANKIND IS IN PURSUIT OF TRUTH,
work done
10/24/16
LET US WORK TOWARDS THIS

18

MONT
H

MAJOR C&I MAINTENANCE

ACTIVITIESACTIVITIES
DURATION
REMARKS
(date &
time)

Feed water hydrazine

5 hrs
Commissioning work
analyser was
done
calibrated,. And it was
taken on line
8 hrs
Commissioning work
All PH , Conductivity
FEB1
done
sensor was fixed . And
5
calibration work done
Super heated steam
4 hrs
Commissioning work
silica analyser was
done
calibrated,. And it was
taken on line
Oxygen analyser was
8hrs
AS per operation
inter changed to APH
instruction
rear side
MAR
CBD tank level Gauge
4hrs
Level not showing
15
isolation valve
properly
direction was inter
changed
CST level transmitter
4hrs
Level not showing
MANKIND IS IN PURSUIT OF TRUTH,
10/24/16
was showing error
properly
LET US WORK TOWARDS THIS

19

C&I MAINTENANCE CHALLENGES

SL.NO

CHALLENGES

ACTION TOOK

PRESENT
STATUS

1.Boiler Bottom
temperature
element and
thermo well

Thermo well
was damaged

Boiler bottom
side thermo
well was
modified

Working
normal

2. Boiler top
temperature
element and
thermo well

Thermo well
was damaged

Boiler Top side

thermo well
insert length
was reduced
200 MM

3. ACC FAN - 4
Float was
OIL level switch jammed

10/24/16

Oil mixed with

grease, so float
jammed

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

Failure less

Capacitance
type level
switch to be
changed

20

C&I MAINTENANCE CASE STUDIES

1.

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

21

REPORTS SYSTEM
DAILY
WEEKLY
MONTHLY
HISTORY
REPORT
SL.NO REPORT REPORT
CARD
1.COMPRESS
1.
NIL
PM
BOILER,
CHECKLIST TURBINE,
ORWrite various kinds
of BOP,CHP,
report you
CHECKLIST
DMPLANT
generate
such
as
daily,
weekly,
2. UPS
monthly,
history
card,
CMMS,
etc
CHECKLIS
T
3. SWAS
CHECKLIS
T
4. CEMS
SYSTEM
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

22

NEW IMPLEMENTATIONS/SYSTEMS
ADAPTED IN THE YEAR
1. Boiler bed bottom thermo well
modification work done.
2. Guard pump -2 was taken DCS mode.
3.ACW header impulse line modification
work done
4.HP heater level transmitter impulse
line modification work done.
5.CEP recirculation Flow transmitter
impulse line modification work done.
10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

23

NEW IMPLEMENTATIONS/SYSTEMS
ADAPTED IN THE YEAR
6. Air dryer bypass valve
modification work done.
7. Swas system wet and dry panel
was commissioning work done. PH,
Silica, Hydrazine, Conductivity,
Phosphate analyzer calibration work
done

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

24

OPPORTUNITIES FOR IMPROVEMENT

IN THE PLANT SYSTEM
SL.NO

OFI-PLANT

ACTION TOOK

PRESENT
STATUS

1.

Combustion
control to be
taken Auto
mode

Logic to be
check

Under progress

2.

EMRV to be
taken DCS
mode

Pressure sensor
calibration done

EMRV not
commissioned

3.

WHILE EB
FAILURE PLANT
COMES TO
HOME LOAD

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

UAT not
commissioned

25

NEXT YEAR PLANS

1. ALL PA, SA, ID suction damper
new air lock relay to be installed.
2. ACC fan Oil level switch New
model to be installed.
3. Combustion control to be taken

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

26

RELATION WITH CLIENT C&I

MAINTENANCE TEAM
1) WE ARE MAINTANING GOOD
RELATION SHIP WITH CLIENT C& I
TEAM.
2) DAILY THEY ARE CONDUCT
MEETING AND WE DICUSSING
INSTRUMENT EQUIPMENT
MAINTANANCE.

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

27

SAFETY AT WORK
MONTH

INCIDENTS

REMEDIAL ACTION
TAKEN

APRIL14

NIL

NIL

MAY14

NIL

NIL

JUNE14

NIL

NIL

JULY14

NIL

NIL

AUG14

NIL

NIL

SEP 14

NIL

NIL

OCT14

NIL

NIL

NOV

NIL

NIL

DEC14

NIL

NIL

JAN14

NIL

NIL

FEB15

NIL

NIL

MAR15

NIL

NIL

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

28

TRAININGS FOR THE YEAR

MONTH

TOPIC/S

GIVEN BY

NO.OF
PARTICIPANT
S

APR14

NIL

NIL

NIL

MAY14

NIL

NIL

NIL

JUNE14

NIL

NIL

NIL

JULY14

NIL

NIL

NIL

AUG14

NIL

NIL

NIL

SEP14

NIL

NIL

NIL

OCT14

NIL

NIL

NIL

NOV14

NIL

NIL

NIL

DEC14

NIL

NIL

NIL

JAN15

NIL

NIL

NIL

FEB15

NIL

NIL

NIL

MAR15

NIL

NIL

NIL

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

29

MY TEAM INCLUSIVE OF.

DESIGNATI
ON

ORG.
CHART

ACTUAL

SHORT

EXCESS

C&I
INCHARGE

01

01

C&I
ENGINEER

04

04

SHIFT
TECHNCICA
N

04

04

HELPER

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

30

MY TEAM IS SUPPORTIVE IN ACHIEVING BEST

MAINTENANCE PRACTICES BECAUSE

1) WE ARE MAINTANING THE PLANT

WITHOUT ANY INSTRUMENT RELATED
PROBLEMS.
2) WE ARE GIVING GOOD
PERFORMANCE AND
ZERO BREAK DOWN MAINTANANCE.

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

31

OPPORTUNITIES FOR IMPROVEMENT

IN MY TEAM
SL.NO

OFI-TEAM

TRAINING
CLASS TO BE
CONDUCTED.

SEMINAR CLASS
TO BE
CONDUCTED.

INTER
RELATIONSHIP
& DISCUSSION
DEVELOPMENT
WITH OTHER
SITE TECH
PERSON

10/24/16

ACTION TOOK

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

PRESENT
STATUS

32

OUR REQUIREMENTS

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

33

QUESTIONS?

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

34

THANK YOU

10/24/16

MANKIND IS IN PURSUIT OF TRUTH,

LET US WORK TOWARDS THIS

35