ENGINEERING DECLARATION

UNIT # 2 2012-13
GM (MTP)

ENGINEERING DECLARATION
August 2012

FOR FINANCIAL YEAR 2012-13

1. 2. 3. 4.

Unit No: Boiler License No: Boiler License validity (date) :

2 (250 MW BHEL Make) CG-246

06.09.2012

Overhaul History (In reverse chronological order) for the past five years :
Operatin g Hrs. Since prev. OH

S. No .

Description

Overhaul duration From To Total

Overhaul category

Cumul. operating Hours

Forced Outages between two overhauls ( nos ) BTL Trip Total

Important & major highlights

Proposed overhaul2012-13 OH for FY 11-12

01/09/ 2012

17/09/ 2012

17 days

Boiler & auxilaries, Turbine & generator Bearing & its Auxilaries -

16831.02

35118.794

10

16/09/ 2010 at 12:36 Hrs

15 days 9 Hrs 14 min

OH For FY 10-11

01/09/ 2010 at 3:22 Hrs

Boiler & Turbine auxilaries,

18287.774

5.
S. No. 1 2 3 4

Unit Milestones / Major Event since inception:

Milestones / Events First synchronization (date) First commercial (date) BTL (Nos.) between two overhauls Trip (Nos.) between two overhauls Data 07.03.2008 15.06.2008 3 7 OH 10 to OH 12 OH 10 to OH 12 Remarks

6. Unit performance History of Past Three years.

S. No. 1 2 3 4 5 6 7 8 9 10 Parameters Generation (MU) Availability (%) Plant load factor (%) Loading factor (%) Total Generation Loss ( MU) DM Make up (%) Heat rate No. of BTL No. of trips. Total forced outage (%) 2011-12 2223.308 99.27 101.24 101.98 24.644 0.44 2286 0 5 0.19 Previous 3 years 2010-11 2141.018 94.90 97.76 103.02 115.872 0.48 2293 2 3 0.89

2009-10 2053.054 93.77 93.75 99.98 166.386 0.70 2315 6 9 4.23

7. Boiler tube leakages detail since last overhauling.

SL. NO

DATE & FAILURE LOCATION DURATION

(i) LHS STEAM COOLED WALL TUBE NO-3 FROM REAR TO FRONT. (ii) LHS STEAM COOLED WALL TUBE NO-1&2 FROM REAR TO FRONT AND LTSH INLET HEADER SHH-9 LHS END DUMMY STEAM COOLED WALL LEFT, ELEVATION IN METRE 41 MTR, PRIMARY FAILURE- LHS STEAM COOLED WALL TUBE NO-3RD FROM REAR,NEAR LTSH INLET HEADER. SECONDARY FAILURE- LHS STEAM COOLED WALL TUBE NO-2ND FROM REAR,NEAR LTSH INLET HEADER FURNACE WW LEFT, PRIMARY FAILURE - FROM CENTER OF WB-26,TUBE NO6 TOWARDS FRONT, SECONDARY FAILURE - FROM CENTER OF WB-26,TUBE NO7 TOWARDS FRONT,

TUBE DETAILS

TYPE OF DAMAGES

NO.OF JOINTS

REMARKS

16/11/10 (11:43 HRS.) TO 18/11/10 (12:43hrs)

STEAM COOLED WALL STRAIGHT TUBE 3NOS EACH1 MTR LENGTH. (MATERIAL SA 210 GRADE-A1 DIA 44.5X4.5MM THICK).

ORIGINAL FAILURE DUE TO FINS WELDING AND SECONDARY DAMAGES CAUSE DUE TO HIGH PRESSURE STEAM CUT. SUSPECTED ROOT CAUSE OF PRIMARY FAILURE: FLUE GAS EROSION SECONDARY TUBE FAILURES DETAIL: SECONDARY FAILURES DUE TO HIGH PRESSURE STEAM CUT.

6 NOS

03/05/12 (12.23 HRS) TO 04.05.12 (12.00 HRS)

ORIGINAL TUBE DIMENSION: TUBE OD-44.5 IN MM THIICKNESS -4.5 IN MM, TUBE MATERIAL :SA 210 Gr-C SECONDARY FAILED TUBE DIMENSION: TUBE OD 44.5 IN MM, THIICKNESS - 4.5 IN MM, TUBE MATERIAL :SA 210 Gr-C

4 NOS

REAPPLICATION OF REFRACTORY CARRIED OUT AT ECO LOWER AND UPPER BANK MANHOLE DOORS LHS AND RHS.

23.08.12 (15.32HRS TO 25.08.12 (07.23 HRS)

ORIGINAL TUBE DIMENSION:TUBE OD-63.5 IN MM THIICKNESS - 5.6 IN MM, TUBE MATERIAL :SA 210 GRC SECONDARY FAILED TUBE DIMENSION: TUBE OD 63.5 IN MM, THIICKNESS - 5.6 IN MM, TUBE MATERIAL :SA 210 GRC

PRIMARY FAILURE DUE TO ATTACHMENT WELDING, SECONDARY FAILURES DUE TO HIGHPRESSURE STEAM CUT

06 NOS

8. Unit / Equipment Performance & Efficiency Evaluation Before Overhauling

Plant performance of Unit # 2 is as follows S.No. Parameters 1 Boiler Efficiency (%) 2 Corrected Boiler Efficiency 3 4 5 6 7 8 9 Gross Turbine Cycle Heat rate Corrected Gross Turbine Cycle Heat rate Gross Unit Heat Rate Corrected Gross Unit Heat Rate Heat rate Deviation Accountable loss Unaccounted loss Pre OH 86.501 86.34 2022 2009 2338 2327 79 54 26

9. Efficiency Tests
1) Turbine Efficiency Test a) Turbine Report Sheet Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 22 23 24 25 26 27 Parameters Unit Load (in MW) MS pressure (in kg/cm2) MS Temp(in oC) 1 st Stage Pressure (in kg/cm2) CRH Pressure (HPTurbine exhaust) (in kg/cm2) CRH Temperature (HPTurbine exhaust) (in oC) HRH Pressure (in kg/cm2) HRH Temperature (in oC) IP Exhaust Pr (in kg/cm2) IP Exhaust Temp (in oC) Extraction Pressure to D/A (in kg/cm2) Extraction Temp to D/A COND. TO DEARATOR Pressure(in Kg/cm2) COND. TO DEARATOR Temp COND. TO DEARATOR flow BFP Suction temp(deg C) MS Flow (in TPH) FW Flow (in TPH) Reheater Spray (in TPH) HPH6 FW O/L Temp(in oC) CRH Flow Calculated Condenser Vacuum Design 250 150 537 136.63 39.57 343 35.62 537 6.96 306.5 Pre OH 254 145.6 535.2 140.7 40.6 349.8 38.2 535.0 7.7 310.2 7.7 310.2 9.9 120.3 621.4 163.5 758.5 758.5 25.3 247.2 701.7 -0.902

612

757.48 0 245.9 665.8 -0.906

b) Turbine Performance Indices 1 2 3 4 Gross Turbine Cycle Heat rate (in Kcal/kwh) Design Gross Turbine Cycle Heat rate (in Kcal/kwh) Corrected Turbine Cycle Heat rate (in Kcal/kwh) Deviation (Corrected Design) (in Kcal/kwh) c) Cylinder efficiency 1 2 3 Parameters HP Cylinder Efficiency IP Cylinder Efficiency Design 86.66 91.90 Pre 86.54 90.52 1951 2022 2009 58

2) Condenser Performance Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Description Load Condenser pressure Condenser back pressure Optimum back pressure Corresponding Saturation Steam Temperature CW inlet Temperature CW outlet Temperature Optimum CW rise Actual CW Rise Optimum TTD Actual TTD Back pressure due to CW inlet (6+8+10) Back pressure due to CW flow & CW inlet (7+10) Variation due to CW inlet temp Variation due to CW Flow Variation due to air/ dirty tubes Total Variation Number of Vacuum Pumps in service CONDENDER DUTY HEAT ADDED MS=FlowMS*(hMS-hFW) HEAT ADDED CRH=FlowCRH*(hHRH-hCRH) HEAT ADDED RH=FlowCRH*(hHRH-hATT) TOTAL HEAT ADDED HEAT LOSS THROUGH RADIATION Pgen Pgen Losses Unit MW Kg/cm2 mbar mbar Deg C Deg C Deg C Deg C Deg C Deg C Deg C mbar mbar mbar mbar mbar mbar nos Kcal/kg Kcal/kg Kcal/kg kW kW kW Date Design 250 -0.906 101.13 91.6 44 33 41.5 8.5 2.5

Pre OH 254.0 -0.897 98.31 93.05 45.25 31.30 40.72 8.50 9.42 4.50 4.53 92.54 97.04 -0.51 5.50 3.27 10.77 1 425758305 73088791 15026650 513873746 254 254000 2540

19

20

21

Total Heat lost CONDENDER DUTY CW FLOW= Cond Duty /((Cwout- Cwin)xdensityx Cp) Outer dia OD Tube thickness (t) Cross -Sectional area Total No of Tubes WATER VELOCITY IN CONDENSER TUBE

Kcal/hr m3/hr mm mm mm2 nos m/sec

256794 293030906 31104 29 1 590 15664 1.870

3) Boiler Efficiency Parameters Unit Load Steam Flow COAL FLOW APH GAS INLET TEMP APH GAS OUTLET TEMP AVG I/L PRIMARY AIR TEMP PRIMARY AIR FLOW AVG O/L PRIMARY AIR TEMP AVG SECONDARY AIR I/L TEMP AVG SECONDARY AIR O/L TEMP SECONDARY AIR FLOW AH INLET O2 % AH OUTLET O2 % AH OUTLET CO2 % AH OUTLET CO % UNBURNT IN FLY ASH UNBURNT IN BOTTOM ASH AMBIENT AIR TEMP DRY AMBINT AIR TEMP WET AMBINT AIR TEMP RH Proximate Analysis Result Total Moisture Ash V.M FC GROSS CALORIFIC VALUE Heat Losses (%) UNBURNT CARBON LOSS HEAT LOSS DUE TO HEAT IN DRY FLUE GAS HEAT LOSS DUE TO MOISTURE IN AS FIRED FUEL HEAT LOSS DUE TO MOISTURE FROM BURNING OF HYDROGEN Date Design 250 740 157 340 132 34 239 310 34 320 571 3.5 5 15.4 75 0.6 1.5 34 28 60.0 12 39 22 27 3600 Design 1.2 4.211 2.067 4.309 08.08.2012 Pre OH 254 758.5 178 246.0 138.7 34.01 291.79 296.8 32.1 302.1 520.8 2.7 5.4 15.8 12 0.3 1.33 27 25 85 13.0 39.2 23.0 24.9 3507 Pre OH 0.412 5.235 2.314 4.048

HEAT LOSS DUE TO MOISTURE IN AIR HEAT LOSS DUE TO SURFACE RADIATION & CONVECTION HEAT LOSS DUE TO RADAITION & UNACCOUNTED HEAT CREDIT( HEAT EQI. OF POWER) HEAT LOSS DUE TO MILL REJECT MANUFACTURE MARGIN TOTAL HEAT LOSS BOILER EFFICIENCY CORRECTED BOILER EFFICIENCY

0.16 0.22 0.54

0.5 13.207 86.79

0.175 0.22 0.74 -0.165 0.020 0.5 13.501 86.50 86.34

4) APH Performance Parameters O2 I/L (Oxygen at APH Inlet) O2 O/L (Oxygen at APH outlet) PA inlet Temp (Tpai) PA outlet Temp (Tpao) PA flow SA inlet Temp (Tsai) SA outlet Temp (Tsao) SA flow Weighted Avg intet Air temperature (Tai) Weightyed Avg outlet Air temperature (Tao) Flue gas inlet temperature (Tgi) Flue gas outlet temperature (Tgo) Flue gas outlet temperature with no leakage (Tgnl) = AL x Cpa x (Tgo - Tai)/(100x Cpg) + Tgo; where Cpa(specific heat of air) = 1 and Cpg (specific heat of gas) = 0.993 A/H LEAKAGE ( in %) A/H Gas side Efficiency (GSE) A/ H - X Ratio Design 3.76 5 34 314 238.6 34 319 570.7 34 317.5 348 132 138.9 Pre OH Pass A Pass B 3.5 3.5 5.7 5.2 37.5 296.8 301.4 32.0 302.1 520.8 34.0 299.5 348.5 341.5 136.4 137.4 151.1 152.6

6.98 66.60 0.74

14.28 62.77 0.74

10.95 61.46 0.71

5)

ESP Performance Date Parameters Load ESP I/L Draft(mmwcl) ESP O/L Draft (mmwcl) Pressure Drop ESP I/L Temp(oC) Design 250 -203 -249 46 132 28.08.2012 Pre OH Pass - A Pass - B 256.5 -167.89 -296.18 -128.29 128.17 -167.43 -296.50 -129.07 128.49

ESP O/L Temp (oC) Temperature Drop Opacity Fields not in Service ID Fan - A Current ID Fan - B Current

122 10 50

113.72 14 47.2 NIL 190.53 191.88

112.01 16

6) Cooling Tower Performance Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PARAMETERS No of cells CW O/L Temp CW I/L Temp DRY BULB TEMPERATURE AMBIENT WET BULB TEMP APPROACH(A) = Cwi - WBT (in oC) RANGE(R) = CWo - Cwi (in oC) EFFECTIVENESS(E) = (RX100)/ (R+A) TOTAL WATER FLOW RATE CALCULATED (CR)=(CW+ACW) EVAPORATION LOSS = CR x (Cwo- Cwin) /675 in M3/hr COOLING CAPACITY in Kcal/Hr CYCLES OF CONCENTRATION = TDS in CW/TDS in makeup MAKE UP WATER CONSUMPTION = Evap Loss /(COC - 1) in M3/Hr CW Flow to each Cell Date Design 14 42 33 28.5 4.5 9 66.7 40000 520at 90% RH design 360000 8 74.29 3077

Pre OH 13 42 32.3 29.2 27.13 5.2 9.6 65 33578.08 479 323577 6.67 84.55 2583

10. Scope of work

BOILER
PRESSURE PARTS Complete Boiler water washing, wall scrapping & buffing. Erection & Dismantling of Quick Erect Scaffolding in first pass up to roof tubes at every 2mt elevation including PSH Thickness survey of tubes Erection of scaffolding and platform in LTSH Terminal Tubes, Re-heater (both banks), Screen Tubes, Hanger Tubes at every 2.0 mtr. elevation and complete platform below Economizer. Pent house & dead chamber cleaning DP test of weld joints & header stub and attachment welding. Shifting, Dismantling, Erection & Alignment of Eco coils (Upper& Lower ) Lifting/Lowering of coils (lower & upper) for inspection Welding of HP tubes up to 76.1mm dia. Strengthening of boiler tubes by weld overlay. Refurbishment of header by weld overlay Fabrication of HP bends up to 76.1mm dia. Alignment of coils (PSH, RH, FSH, LTSH, Eco) Fixing of protection shields /shrouds Fin/skin casing welding by tested welder Application of Plastic Refractory Application of insulation & cladding sheet Drum cleaning and inspection Wall blower distance setting & sleeve fitting Servicing of buckstays, manhole, peephole ( servicing of all buck stay pins, boiler expansion indicators, manholes, peepholes, tie rod of dog house & pent house header hanger supports.) Repair & Re-installation of bottom seal plate and Woven Wire Mesh Replacement/repair of fuel burners replacement of 24 Nos. coal nozzle , repairing of all oil & air bucket, servicing of tilting mechanism ,repairing of wind box & servicing of SADC. Cleaning of 12 Nos. coal pipes with water jet. Servicing of oil, air & steam atomizing lines valve firing floor. Reversal of coal pipe orifice. Rotation of coal pipe (2 - 6 mtr. length) Replacement of coal pipe Repairing of coal pipe by patch welding of 500mmx500mm piece Inspection and Servicing of coal pipe coupling Alignment of coal pipe Inspection/repair/replacement of coal pipe bends Servicing of coal burner isolation gate. Cold Air velocity Test BOTTTOM SEAL TROUGH Inspection of seal plates & thorough cleaning of seal trough Inspection & checking of quenching nozzles & its direction Repair/ Replacement of SS Mesh & Bottom Seal plate AT BAH

VALVES Overhauling Of HP Valves - Drain & Vents, Root Valves Overhauling & Pressure setting of safety Valve SV1 to SV5 FUEL FIRING SYSTEM (COAL & OIL BURNERS, SADC ) Replacement of 24 nos coal nozzle ,servicing & alignment of burner tilts Repairing of Wind Box & Servicing Of SADC & its synchronized movement Condition checking of oil & air compartments Healthiness checking of air guide vanes inside wind box Inspection of all attachments in the burner zone near transition tubes to check whether wind box is properly loaded on the water wall tubes & no attachment is missed out during replacement of burner transition tubes Thickness measurements of coal pipes Condition based replacement of coal pipes Inspection of elbow/bend , orifice & victaulic gasket randomly. Servicing of knife edge gate valves for coal nozzle

APH A & B All Baskets to be taken out &cleaned with High pressure water jet. Templates to be made for covering the cleaned baskets so that foreign material does not fall into the basket. Renewal of Outboard baskets (48 nos.) / APH Seals And Baskets Inspection & Arrangement for Basket Cleaning, Seal setting (replacement of damage seals) Guide & Support Bearing, rotor post aluminum seal opening & inspection, Hot end & cold end rotor post seal repair/replacement & kao wool packing Lub oil system servicing of support & guide bearing Guide & support bearing oil flushing & oil changing Attending hot air leakages in guide bearing Air heater soot blower servicing & angle setting Inspection of Gear box, fluid coupling & oil changing & realignment. Servicing of Air motor Support & Guide Bearing alignment after seal setting Repairing of APH duct from GD1 & 2 to APH Hopper Checking of healthiness of fire fighting system- replacement of eroded headers, cleaning/replacement of nozzles DUCT & DAMPERS OVERHAULING Cleaning, Inspection and thickness measurements of ducts Repair , replacement of eroded bracings, duct plates & guide vane plates/Expansion Bellows of PA & FD , ESP I/L & O/L ducts with SAIL HARD/ SELMA STEEL Servicing & repair of all dampers and gates along with seals Replacement of eroded guide vanes Checking of the operating mechanism of all the dampers & gates Checking of the healthiness of the blower Practices to be followed during Overhauling of Boiler Steam/air blowing of new tubes before installation Sponge ball test of new coils/bends to be done before installation

All vertical tubes to be cut with grinders only Immediate capping of tubes to be done after cutting Deployment of tested cutter for tube cutting Deployment of tested HP Welders for welding of joints. All attachment welds to be done by tested welders Attachment welds to be done by 2.5mm size electrodes only All supports / clamps to be restored to original FANS Inspection, repair & maintenance of PA Fans, FD Fans, ID Fans, Seal Air fans. COAL MILL & FEEDER. Replacement of Grinder Roller of Mill 4A & 4C Replacement of Bullring Segment of Mill 4A, 4B, 4C & 4D Replacement of Clamping Ring of Mill 4A, 4B, 4C & 4D Hard facing Inside Mill & JOC Servicing/Replacement of of Journal Pressure Spring Replacement/Servicing of Classifier Vane Assembly. ESP Thorough internal inspection of ESP electrodes to locate defects and repairing. Cleaning and inspection of shaft insulators, support insulators and replacement of any damaged insulators. Screen tube and Field suspension rod. GD Test to be done

TURBINE

Overhauling of LP Turbine Module Replacement of Hydrogen Seal Rings of Generator. Overhauling of Generator & Exciter Inspection of Bearing Nos. 1 to 7 and H2 Seal Ring. Overhauling of MOP, MS Strainer (LHS), HRH Strainer (RHS), PHE A & B, CEP - 2A, 2B & 2CProvided we receive the Dummy sleeve reqd. for modification of CEP. Servicing of Turning Gear, HPSV, HPCV, IPSV, IPCV & its Servomotor, HPBP Valves, HPBP Spray valves, Butterfly Valves, Air Release valves. Checking of Governing Characteristics Cleaning of BFP & Booster pump suction strainers, De-aerator, FST, OCST & DMCW Tank, Hot well, ACW Strainer Elements, Cooling Tower basin Transferring of Oil in MOT to COT, Cleaning of MOT and again transferring of oil from COT to MOT. Condenser Tube cleaning by Bullet Shot Method and applying of Chemical Resistant Coating in Condenser tube sheets & water box Carrying out Condenser Flood test, Air/H2 leak test of Generator, Hydro test of H2 & Exciter Coolers CW Duct Butterfly valve inspection and servicing Attending identified leakages and defects booked by Operation dept. CT Basin Cleaning, Cooling Tower nozzles & drift eliminators cleaning, repairs & replacement

Electrical
Overhauling of Generator Generator overhang portion NFT Test & Inspection. Exciter & PMG Dismantling, inspection & testing. NGR, NGT & SPVT inspection, tightness checking & testing. Preventive maintenance of Gen Aux Panel- ECB, CFA & CTE02 Panel. Transformer Overhauling GT General Checking & OLTC inspection, UAT A&B oil filtration, OLTC inspection, ST2- OLTC inspection & general checking. Testing of GT , ST & UAt-2A &2B. Unit & station auxiliary transformers cleaning, inspection, tightness checking & testing. 6.6 KV HT SWITCHGEAR(5 Nos of MAIN PLANT & BOP) - inspection & cleaning of bus bars & feeders, connection tightness of power and control cables, sealing of spare holes ,inspection of CT's and PT's. 415 V LT SWITCHGEAR (17 Nos. of MAIN PLANT & BOP)- inspection & cleaning of bus bars & feeders, connection tightness of power and control cables, sealing of spare holes ,inspection of CT's and PT's. H.T.MOTORS OVERHAULING (15 nos )- ID Fan A&B, FD Fan A&B, PA Fan A&B, Coal Mill A,B,C,D &E, 1 BFP, CEP- A, B&C. Cleaning, varnishing, painting, bearing inspection & replacement and testing. LT MOTORS OVERHAULING (81 Nos.) - Cleaning, varnishing, painting, bearing inspection & replacement and testing. Wall & soot blowers cleaning, inspection, motor bearing replacement if required. MOV Actuators overhauling Cleaning, inspection, grease & oil replacement. AVR cleaning, inspection, tightness, field breaker alignment testing, & Dynamic Testing GRP-Cleaning, inspection, tightness, relays testing, annunciation checking. ESP - BAPCON, RAPCON Panel, Rectifier Transformer Overhauling &testing, PMCC,MCC & Dry transformer overhauling. BATTERY AND D.G. SET- Capacity test of 220 V UNIT-2 Main Battery & UPS battery, Battery charger cleaning, tightness & inspection 220 KV Switchyard bay: Breaker, CT, Isolators general checking/ testing/ maintenance.

C&I
TG AREA Cleaning of field equipments, JB's and ensuring the tightness of all connections. Checking and calibration of all critical instruments related to plant ,equipment tripping, interlock and efficiency analysis. Checking and calibration of control valves and hydraulic actuators. Checking of TSI pick up response and calibration. Servicing of UPS & ACDB To install and commission electronic level switch in CRH. Checking of protection interlock of turbine and its auxiliaries DCS storian upgradation and HMI software setting and checking.

Cleaning and checking of the DCS cards. Flow nozzle of LPBP spray to be shifted before MOV. To Replace HP exhaust thermocouples. To replace MOT level transmitter with radar type LT to improve reliability and accuracy. To install isolation valve in the downstream of CEP vent solenoid valve. To shift orifice plate of DM makeup flow from downstream to upstream of CV. Skin type RTD to be installed in BFP recirculation line to detect RC valve leakage. RTD to be installed in place of temperature switch in Vacuum pump for improving condenser performance. ATRS/ATT establishment to be checked and to be made operative. BOILER AREA To check the overall instrumentation of HFO Station (FM,HOTV &HOFCV), LDO & Air Station (FM,LOTV&LOFCV) & Station for Atomising Steam at Operating Floor To check the operation of Oil Burner - AB Elevation (AANV,ASNV,HONV & LONV) and for CD & EF Elevation (AANV,ASNV & HONV) Servicing/checking of HEA Spark Rod/Igniter advancement / Flame Scanner functioning at all elevations To check/replace the T/C's of HOT end & cold end of APH-A&B, RTD of guide bearing of APH. To check/inspect & Calibrate both Oxygen probes, PA Header Pressure Transmitters (03 Nos.) & Switches (05 nos.), Furnace Pressure switches (06 NOS) Cleaning & Calibration of SADC Power cylinders (56 Nos.) Cleaning & Calibration of all Power cylinders for ID, FD, PA, HAD,CAD, HAG & Burner Tilt (Total 30 Nos.) Checking and calibration of all critical instruments related to plant equipment tripping, interlock and efficiency analysis. All auto control loops performance checking and fine tuning. AHP AREA ESP level probe checking. ESP vacuum transmitter calibration Slurry pumps interlock & protection checking Overhauling of all Power cylinders (Total 90 Nos) Buffer hopper purging solenoid valves orientation to be changed from horizontal to vertical.

ASH HANDLING SYSTEM Bottom Ash Hopper Refractory work. Seal trough cleaning and repairing. Inspection, Servicing and Assembly of fluidizing pads (128 Nos.) Replacement of all gaskets between hopper to M.S. adaptor & M.S. adaptor to knife gate valve Inspection, Servicing and Assembly of all MHV (72 Nos.) of ESP, Duct and APH hoppers and their segregating valves (29 Nos.) Inspection, Cleaning and Replacement of worn out parts of all collector towers. Inspection , Replacement of worn out parts of rotating segregating valves of all Air lock vessels. Removal, Inspection, Replacement & Assembly of fluidizing pads of buffer hopper & air lock vessels

Inspection, Replacement of damaged bag, cage of bag house Inspection & replacement of worn our parts of feed gate assemblies, hydro ejector. Dismantling of flushing apparatus, inspection & replacement of gaskets, nozzles, pipe, fittings, valves and reassembly of flushing apparatus in Economizer Hopper

11. Improvement & Modification Work

TMD BMD C&I Modification of CEP. Installation of dummy stage in place of 2nd Stage, for existing 3 No. CEPs. Corrocoat Coating of CW & ACW Pumps Hydraulic passage of Unit#02.

Application of Plastic Refractory. Burner nozzles to be modified and replaced during Overhauling.

Relocation of temperature element of after reheater desuperheter to avoid measurement error. Flow nozzle of water injection flow of LPBP to be shifted before motorized valve as existing installation does not cover flow through motorize valve .and to avoid unit tripping in case of failure of pneumatic valve. To replace head type RTD/Thermocouples with head less ones in critical areas like exciter hot air temperature & seal oil temperature etc. To replace MOT level transmitter with radar type LT to improve reliability and accuracy. Installation of RTD in place of Temp switches in Vacuum pump for monitoring and control of temperature and improving condenser performance. Provision for remote monitoring of HPBP system oil pressure and control of HPSU pump. BFP trip contact of dearator level low to be derived from transmitters in addition to switches to improve reliability. To install isolation valve in the downstream of CEP vent Solenoid valve. To shift orifice plate of DM make up flow from downstream to upstream of CV to avoid measurement errors. UCP,ATRS & ATT establishment. Skin type RTD to be installed in BFP recirculation line to monitor RC valve passing. Buffer Hopper purging SOV'S Orientation to be changed from horizontal to vertical to improve reliability. To install & commission electronic level switch in CRH. Main Steam temperature low trip contact to turbine to be derived from soft to Hard as an endeavor to improve reliability. Relocation of Local Vibration Indicator Junction Boxes for ID, FD&PA Fans.

ELD

Auto Bus transfer scheme at CTPMCC in UNIT-2 6.6 KV HT Board H.T. Motor tripping from Bus PT at main plant in UNIT-2 Redundant Power supply arrangement of AVR For unit -2 Provision of all H.V. motors over load alarm of unit -2 at CCR LVS Generator SPVT all voltage transformers of Prayog make shall be changed with Pragati make voltage transformer total nine numbers 6 Amp MCB to be provided in place of low rated MPCB in motor feeder module

12. Pending defect & Opportunity Based jobs Pending defects are available on line, being attended and updated daily. Pending defect list to be taken before one month of unit shut down.

13. Justification/Evaluation of Overhauling

1. For Boiler license renewal, validity is up to 06/09/2012. The Boiler license is to be renewed up to for further two years duration. 2. During Annual Overhaul essential activities shall be carried out for safe and reliable operation of the unit for next two years. 3. Overhauling of LP Turbine Module & Generator to be done. 4. Due to Furnace Fouling Flue gas Temperature, SH spray & RH spray are of higher side, which shall be reduced by High pressure Jet cleaning, scrubbing of Boiler etc. This will reduce the Heat rate losses and improve the plant efficiency. 5. Due to air ingress in the boiler and ducts, ID fan currents is on higher side, which can be reduced by thorough inspection of ingress points in BA hopper, Seal trough area, Replacement of rope gaskets in ESP manhole doors. 6. Air Heater Air ingress is on higher side, Air side gas side efficiency is also poor which requires APH seal setting, cleaning of basket and APH hot water washing. 7. Cleaning of ESP during shutdown will not only improve the performance but will benefit help to meet the requirements of pollution norms. 8. Condenser cleaning by high pressure bullet jet and condenser flood test during OH will also help to reduce any type of losses in performance of unit. Cooling Tower cleaning during AOH will also benefit us for condenser performance improvement. 9. Passing of High pressure Energy drains has been already identified, which shall be attended during OH.