LONG TERM PLANNING AND OVERHAULING PRACTICES IN NTPC

WHY OVERHAULING IS REQUIRED ?

Performance Reliability Availability Safety Environment Cost Statutory Requirement

PRASECS

PERFORMANCE
Generation Heat Rate Parameters Specific oil consumption Auxiliary power consumption
Motor current Capacity deterioration Utilising stand by eqpt.

RELIABILITY
Routine and repetitive maint. Poor performance of eqpt. Unplanned Breakdowns
High vibration of eqpt. Abnormal noise High Temperature Leakages

AVAILABILITY
ABT Availability of stand by eqpt. Availability of complete stream

SAFETY
Safety of the equipment Safety valves Poor condition of internals Safety of electrical eqpt. Condition of flow path

ENVIRONMENT
Flue gas emissions
Air control act

Noise Ash water Effluents

COST
Cost of generation Coal input Water consumption Oil consumption Auxiliary power consumption

Statutory requirement
Boiler certificate renewal

WHEN TO DO OVERHAULING ?
Summary of

PRASECS

Grid condition Customer requirement CERC Clearance Condition of other units of the station MOU Target

LONG TERM PLANNING

Life cycle plan for 25 30 years Regional Eight years rolling plan Station Eight years rolling plan Engineering declaration Annual location plan Spares procurement plan

LIFE CYCLE PLAN

Likely trend of replacement of the equipment/parts which are likely to fail before the life expectancy Factors for replacement
Coal quality Creep life of various components Equipment duty conditions Wear rate Behavioural trend of plant/ equipment & its past history RLA Reports

MAJOR EQUIPMENT TO BE COVERED IN LIFE CYCLE PLAN

Gear Reducers Slurry pumps Coal crushers Conveyor Drives in CHP Chemical piping

Contd
Boiler Pr.Parts
Super heaters Re-heaters High Pr. Valves Safety valves

Contd
Turbine & Aux.
Turbine rotor blades Turbine bolts Boiler feed pump rotor H.P. Heater coil

Contd
Electrical
H.T.Motor Transformer Switch gears Cables

Regional Eight years rolling plan

Minimum number of units at a time Regional electricity boards Regional grid demand Capital investment and revenue budget Unit/station merit rating based on efficiency and economics of generation

Define region into station/plant & areas Engg input From similar plants Statutory requirement

Consider plant life & potential Problems In each station/unit

Maint. Engnr Input Plant Betterment plans

Formulate repair plans with cost data

Resource Spares & materials

Evaluate

Resource Skill and T&P Management input

Interim plan

Region/station rolling plan Eight year rolling plan Flow chart

Station location plan

Station Eight year rolling plan

Detail plan for first three years Diagnostic inspection and major replacements in subsequent years Modest updating each year

Station annual location plan

Detailed account of operation and maint. Of the current year and plans for the next year. The plan should consist Unit merit rating based on its performance in the last one year. Justification of heavy expenditure for improvement and modifications Resource availability analysis Fuel cost Generation cost

ENGINEERING DECLARATION
Brief review of the past performance of the unit Objectives of the proposed overhaul Scope of work Resource plan Returns in terms of gain in reliability and efficiency Engg declaration to be issued 24 months ahead and reviewed periodically (six monthly)

Format of Engg. Declaration

Unit no Boiler license no Boiler license validity Overhaul history Unit mile stones/ Major event Unit performance history Root cause analysis on Boiler tube leakages and action plan Root cause analysis on trip and action plan

Contd
Major eqpt. Failure history Parameters assessment Work module Financial justification Techno economic evaluation Bar chart Exception of condition monitoring reports

Planning process of unit outage

Pre shut down planning activities Shut down activities Post shut down activities

Pre shut down planning activities

Plan to start from the time unit is synchronised. Engg declaration Spares and materials schedules Quality plans Recommissioning Schedules Defect work orders pending PRE SHUT DOWN SURVEY

Resources
Spares & consumables Manpower Contracts Special T&P Material handling equipment like cranes, lifts and transport Availability of manufacturing facilities Communication facilities

Contd
Testing facilities like radiography, hydro test etc. Temporary store & office cubicles Dispensary & ambulance at site General amenities for additional work force Input from other departments

PRE SHUTDOWN SURVEY

Equipment general condition Condition of bearings, filters and coolers Condition of APH
Pressure differential Heat pick up across APH Parameters of primary ,secondary air & flue gas Oxygen in flue gas

Contd
ESP
Ash evacuation capacity Heating system Flue gas emission Leakages through manholes ESP inlet & outlet Temperatures.

Coal mills
Reject rate Coal fineness Leakages

Contd
Boiler
Boiler expansion Leakages through manholes, peep holes Coal leakages Burner tilt mechanism Soot blower status

Valves & Fittings

Steam leakages Steam passing Local/remote operation

Contd
Ducts & Dampers
Hot air leakages Air suction in the gas path Ash leakages Leakages at expansion joints Dampers operation from local & remote Dampers isolation Duct insolation

Contd
Turbo Generators
Bearing condition Vibration & Temp Oil leakage Analysis of lub oil Operation of control valves Leakage of hydrogen Stator water DP

Contd
Motors
Bearing vibration Lubrication & Temp. rise

Transformers
General condition of oil Dielectric strength

Execution
Unit shut down Issue of PTWs Daily overhaul review meeting Follow up of the bar chart Filling the quality check sheets Return of PTWs Recommissioning activities Boiler hydro test Unit light up Unit synchronisation

Post overhaul review

Deviation from the planning if any Performance of contracting agencies Plant parameters review Overhaul report

SCOPE OF WORK

PRESSURE PARTS
WATER WALL
S-Panel: All corners & L&R walls inspn. & repairs Burner transition & corner tubes inspn. & repairs, TT survey in erosion prone areas, HP Jet cleaning, DPT of scallop bar, support & ww tubes in dead chamber, Bottom ring header inspn. WW screen & hanger tubes inspn. Coils lifting (condition based), Inspection of Bifurcation bends, Cassette baffles & Terminal tubes inspection DPT of hanger tubes & TT survey Spacer tube healthiness checking & TT survey DPT of Lugs to tube welding Scissor tubes sleeves, lugs inspn. & repairs and DPT of Lugs to tube welding, TT survey TT survey in Screen tubes, tubes near manholes, Gap between LTSH coil & steam cooled wall, Eco coil& SCW, mechanical rubbing due to cassette baffles, stubs of SHH-4A &4B

LTSH PLATEN SH / FINAL SH DIVISIONAL SH STEAM COOLED WALL

PRESSURE PARTS
REHEATER ECONOMISER

CONTD..

Spacer tube healthiness checks & lugs inspn. ORIFICE FIXING ? & TT survey Coils lifting (Condition based) DPT of root joints of stubs of Inlet header Cassette baffles & hanger tubes inspection & TT survey

DRUM
HANGERS SAFETY V/Vs & ERVs

Drum inspection Drum J-bolts inspn. & DPT

Pre O/H & Post O/H readings comparision Survey of Cold readings & Adjustment, if any Defective Safety valves & ERVs (Condition based) overhauling/Servicing

SOOT BLWRS
PENT HOUSE

Soot blowers overhauling & LRSBs servicing

Inspection of supports, headers, vents, DPT of roots, attachment weld joints& all header joints

PRESSURE PARTS
BURNERS

CONTD

36 NO.S of Coal nozzles replacement Air/oil nozzles in-situ repair (condition based) SADC/BURNER TILT CHECKS Repair & Rectification of defective portion of joints after pre-overhaul survey Erection of QES and Thorough inspection & cleaning of Water walls, Divisional panel Cleaning, Inspection & repairs Expansion indicators checking for any fouling problems

NMEJs
QUICK ERECT SCAFFOLDING WIND BOX BOILER EXPANSIONS

HP VALVES
BOILER SUPPORT SYST

CC pump- discharge v/v bonnet leakage, CBD v/vs, MS, Spray v/vs, root valves gland packing replacement
Boiler support systems checks as per LMI

ROTATING MACHINES
MILLS FEEDERS DAMPERS & GATES FANS AIR PRE HEATERS
2 No.of Mills Overhaul , Lub station servicing 8 no.of RC feeders overhauling Dampers & gates overhauling & Passing problems rectification All fans servicing, Blade pitch control servicing, silencer cleaning, Visual inspection of shaft, welds & NDT. Lub station servicing. Damaged baskets replacement, if any Radial / Axial seals inspn, repairs & replacement All bearings/ gear boxes inspection Overrunning clutches problems attending. SCAPH heat transfer areas inspn , cleaning & repair Air & Gas duct inspection & repairs Repair of defective dampers & servicing of diversion dampers

DUCTS & DAMPERS

ASH HANDLING SYSTEM

BOTTOM ASH Repair of refractory, Seal trough & view glasses inspection & cleaning, Clinker SYSTEM
grinders rollers (2 sets) replacement, SS pipes replacement, Feed gate seal & barrel replacement & attending to passing problems, Bottom ash nozzles inspection BA discharge new lines connection

FLY ASH SYSTEM

Fly ash slurry line rotation/ replacement, Collector tanks & Air washers inspection, Vacuum line valves servicing, All vacuum lines washing, Vacuum pumps servicing, Collector seal boxes repairs. Emptying of all hoppers All ESP internals cleaning,inspection/ repairs

ESP

TURBINE & AUXILIARIES

MAIN TURBINE TDBFPs
CF trip oil line modification for proving ATT, & Turbine Governing characteristics checking, Turbine actual over speed testing Euroflex coupling inspection, Turbine actual overspeed test, MDBFP-2C discharge NRV replacement, ACV & MCV pilot valves servicing & recirculation control valves inspection & repairs. TDBFP-2A&2B exhaust duct insulation & plastering DMCW pump-B overhaul & suction strainers cleaning DMCW,ACW & CW system butterfly valves servicing (600 NB: 6 no.s, 800 NB : 8 no.s) PU coating inspection & repairs, Self cleaning filters inspn Condenser Water box tube cleaning, FRE lining inspn Hotwell & Deaerator cleaning & condenser flood test CEPSs suction strainers cleaning. CW duct PU coating inspection & repairs. Turbine MAL valves, HTPRDS spray valves

DMCW & ACW

CONDENSER CW DUCT VALVES

OFF-SITES (MECHANICAL)
CW PUMPS CW pump- 3,4 & 5 volute inspection for poly -glass coating. CW pump butterfly valves inspection & operational checks CW inlet & Outlet duct inspection PU coating repairs. &

CW DUCT

COOLING TOWER

CT nozzles inspection / cleaning CT nozzles & drift eliminators repairs / replacement. CT basin cleaning.

EM-LT SWGR
LT switch gear sections overhaul Bus/Modules/breakers/relays/contact ors/transducers/timers Cable shifting / interchanging Testing of protections of incomers/ bus couplers / auto change over schemes as per LMI

EM-SWYD / HT SWGR
Insulators replacement CTs replacement Bus tightness HT switch gears PM

EM-GENERATOR
Stator & Rotor Inspection Core inspection Hydrogen & Exciter coolers servicing Exciter servicing Testing of excitation as per LMI Inspection & protection of water cooled generator stator winding Prevention & detection of generator rotor earth faults as per LMI

TRANSFORMERS
Transformers cleaning OLTC, Conservators cleaning Protection elements checking Silica gel replacement Oil sampling Oil flushing Testing

HT & LT Motors
Overhauling of motors Servicing of motors Bearings Oil replacement / Greasing Lugs inspection Fan inspection

LIGHT-UP TO SYNCHRONISATION
ACTIVITY LIGHT-UP TO SYNCH. LIGHT-UP TO SAFETY V/V FLOATING START SAFETY V/V FLOATING DURATION SAFETY V/V FLOATING TO TG 3000 RPM ELECTRICAL TESTS DURATION UNIT-1 UNIT-2 UNIT-1 UNIT-2 UNIT-1 (2003-04) (2004-05) (2004-05) (2005-06) (2005-06)

25 Hrs

24.5 Hrs

20.8 Hrs

20.0 HRS 14.4* HRS 4.5 HRS

18 Hrs 12.5 Hrs 4.4 Hrs

7.2 Hrs 6.7 Hrs

6.5 Hrs

5.5 Hrs

5 Hrs

3 Hrs

5.2 Hrs 3.3 Hrs

4.5 Hrs

0.8 HRS
5.0* HRS

0.9 Hrs
4.3 Hrs

5 Hrs

7.75 Hrs

6 Hrs

PRESSURE PARTS (Contd)

QUICK ERECT SCAFFOLDING

UNIT-1 UNIT-2 UNIT-1 UNIT-2
(2003-04) (2004-05) (2004-05) (2005-06)

QES ERECTION

8.5 DAYS

7.0 DAYS

5.5 DAYS

5.5 DAYS

QES DISMANTLING

4.5 DAYS

2.0 DAYS

2.9 DAYS

3.0 DAYS

FUEL OIL CONSUMPTION

UNIT # I # I YEAR 2003-04 2004-05 HFO KL 228 243 LDO KL 224 38 TOTAL KL 452 281

# II
# II #I

2004-05
2005-06 2005-06

251
148 -

151
141 -

402
289 170

THANK YOU