Event Ana U#7,2006 - Completed

Unit-7
EVENT ANALYSIS
2006
INDEX
POG/VARIOUS REPORT/EVENT ANALYSIS
Sr
No.
Event
No.
Date
Time
(Hrs)
Reason
01/2006
23/02/2006
20:55
Water wall tube leakage at corner no. 3
M1/2006
26/02/2006
17:00
No indication Liquid in Gen. high on CPU and on PMS.
02/2006
04/04/2006
13:51
M3/2006
09/05/2006
17:28
M5/2006
12/05/2006
15:22
Load variation from 440 to zero MW C/M-EF tripped.
03/2006
13/06/2006
04:58
Front Reheater tube leakage.
04/2006
15/06/2006
09:13
M6/2006
14/07/2006
09:02
M7/2006
31/08/2006
09:19
10
05/2006
22/10/2006
16:00
11
06/2006
30/10/2006
10:48
12
M8/2006
01/11/2006
14:00
13
M10/2006
01/11/2006
14:50
T-G set shaft vibrations are maintaining high.
14
07/2006
06/11/2006
15:37
Boiler tripped on Loss of all fuel DDC panel 24 V DC

power supply failure. G2 Battery charger filter choke up.
15
08/2006
11/11/2006
22:16
LTSH Inlet header tube leakage.
16
M11/2006
14/11/2006
---
Turbine tripped on DN/DT protection on last five

synchronizations while rolling turbine from 360 to 3000 rpm.
17
09/2006
20/11/2006
16:12
Economizer (Upper) tube leakage.
18
10/2006
23/11/2006
23:03
19
M12/2006
24/11/2006
21:42
20
M13/2006
28/11/2006
18:44
T-G Desk CRT-G1 & G3 turned magenta.
21
M14/2006 02/12/2006
10:06
PRDS pressure & temp. increased suddenly & safety valves

started floating.
22
M15/2006
11/12/2006
08:17
Generator Stator Upper Bar T-39 PW outlet temp. high.
23
M16/2006 14/12/2006
06:46
24
M17/2006 12/12/2006
16:50
T-A set tripped on Condenser vacuum very low protection.

LDO pressure control drive card failed.
Seal air fan-7G tripped on Master Trip Relay operated
protection.
Set tripped on Gen. Overall differential protection. Fire

observed above Gen. Casing at turbine end.
Station Xmer-5 tripped with ST-5 trouble indication on UCP.
Station Xmer-5 tripped with Earth fault & MTR Trip
indication on GCR.
Set withdrawn due to Abnormal rise in temp. of Generator
stator bar no. 32 (Repaired Bar)
Set hand tripped due to HPT Breech Nut heavy steam
leakage.
TSC Higher Margin for Turbine Loading is maintaining less
than 5.
Set w/d for turbine balancing due to shaft/ bearing pedestal

vibrations high.
C/F-F tripped on Tachogenerator feedback conveyor belt
found Burnt.
Seal oil temp. after cooler shoot upto 650C & again become
normal.
T-A set vibration Analysis report indicates rubbing
phenomena at bearing no. 1 to 5.
EVENT ANALYSIS
UNIT NO: 7
Event no: 01/2006
Date: 23/02/2006
Time: 20:55 Hrs
Load: 505 MW
Coal cycle in service: AB, CD, EF, GH
Oil Support: Nil
Description: TA set hand tripped due to boiler tube leakage (water wall) at corner no.3 (Tube no.7) also
screen tube water wall corner no.2 tube no. 1 found burst due to starvation (from RHS).
Window Indication appeared / Relay operated: RPP (32 G2 relay) operated, Indication appeared on UCP
Boiler Light up:
Time 22:59 Hrs
Date 25/02/2006
TG set synchronisation: Time 07:22 Hrs
Date 26/02/2006
Problem faced during bringing back the set on bar:

1). MS-1 did not open electrically, hence bypassing the torque switch & then valve opened.
2). LHS HP stop valve spindle leak off spindle broken in close position.
3). ATRS operation constraints.
Analysis: Due to water wall tube leakage, the boiler parameters get disturbed. DM water make up increased
from 34 to 400 T/Hr.
Work Carried Out: 1) BM-II section: Shut down/preventive maintenance work carried out.
2) TEST-II section: Shut down/preventive maintenance defect work carried out.
3) TM-II/ EM-II/I&C-II section: No work carried out.
Recommendations:
Short Term: 1). Leakage was attended by metal deposition in eroded portion.
2). Protective plate welded before the bend at corner 1 to avoid erosion.
3). Overheated screen tube on down stream replaced.
Long Term: Procurement of new bend in air compartment for replacement is being initiated.
Remark:
GM-II: 1). It will be better if we replace similar bends of all corners of all units 5, 6 & 7 in overhaul.
2). We may ask for bends with slightly more thickness while calling others.
3). We may also practice replacement of these bends in every capital overhaul of the unit.
----0----
EVENT ANALYSIS
UNIT NO: 7
Event no: M1/2006
Date: 26/02/2006
Time: 17:00 Hrs
Load: 445 MW
Coal cycle in service: AB, CD, EF, JK
Oil Support: Nil
Description: Generator LLD middle (MKA-22CL001) at 05 Litres of water removed. No Indication liquid
in Gen. High appeared on UCP and also on PMS also.
Window Indication appeared / Relay operated: Nil
Boiler Light up:
Time ---- Hrs
Date --/--/----
TG set synchronisation: Time ---- Hrs
Date --/--/----
Problem faced during bringing back the set on bar: Nil

Analysis: 1) Moisture in Generator high appearing frequently on PMS, Hydrogen drier silica gel replaced on
11/02/06 2) I & C II staff check indication, Liquid in Generator high.
Work Carried Out: I&C-II section: Six Nos. of liquid level detectors of capacitive probe type are provided
in scheme for detection of presence of liquid in Generator.
These locations are as below.
1.
Liquid in Gen. Turbine end
-MKA21CL001
2.
Liquid in Gen. Center
-MKA22CL001
3.
Liquid in Mains Lead Bottom-MKA23CL001
4.
Liquid in Main Lead Bottom -MKA23CL011
5.
Liquid in Main Lead Top
-MKA24CL001
6.
Liquid in Main Lead Top
-MKA24CL011
In Healthy Condition Simultaneous Operation of Probes at Sr.No.II to V leads to Generator tripping.

Liquid in Gen high annunciation is provided on UCP & PMS event log and appears if any one of the probes
detects presence of liquid.
Change in capacitance of the probe due to presence of liquid is sensed and an amplifier logic is Fail
rate high i.e. failure of Aux .230V AC supply to amplifier unit or probe wires open circuit leads to operation
of relay. Probes MKA21CL001 and MKA22Cl001 through which water was drained were tested on 27.02.06
vide E.P.No. 34736. It is observed that operation of both probes in oil water as liquid is O.K. But relay
contacts are not changing over properly.
This proposed to replace amplifier units of both probes from available spares, it is also proposed to test
remaining four probes and their amplifiers in next unit shut-down, checking of all six LLDs is also to be
included in preventive maint, schedule with a frequency of 3 months.
TM-II / EM-II / BM-II / TEST-II section : No work carried out.
Recommendations:
Short Term: Probes MKA21CL001 & MKA22CL001 through which water was drained were tested .It is
observed that operation of both Probes in oil water on liquid is OK but relay Contacts are not Changing over
properly which will be attended in unit S/D.
Long Term: Amplifier units of both Probes will be replaced in unit S/D and remaining & Probes will be
tested along with their amplifier unit. Checking of all six nos. LLDs is also to be included in preventive
maint. Schedule with a frequency of 3 month.
Remark:
SE (O) II 1) H2 cooler leakage suspected. Cooler to identity and to attend in next shutdown.
2) Both probe Amplifiers to replace and all LLD healthiness to check in next shutdown.
----0----
EVENT ANALYSIS
UNIT NO: 7
Event no: 02/2006
Date: 04/04/2006
Time: 13:51 Hrs
Load: 500 MW
Coal cycle in service: AB, EF, GH, JK
Oil Support: Nil
Description: Load suddenly dropped from 500mw to 35MW causing (1) LP by pass opened 100%
(2) Condenser vacuum drop down to very low (condenser pressure very high) hence turbine tripped at 13:51
hrs and Boilers tripped on Drum level very low at 13:52 hrs.
Window Indication appeared / Relay operated: ---Boiler Light up:
Time 14:31 Hrs
Date 04/04/2006
TG set synchronisation:
Time 11:34 Hrs
Date 05/04/2006

1). Water was coming continuously through CRH atm Drain (CR-07) valve.
2). Barring gear speed reduced to zero rpm due to jamming.
3). Unit was synchronized at 09:28 hrs. on 05/04/2006 and TA set tripped at 09:29 hrs. on differential turbine
casing temp. S.O.E. (II) attached.
Analysis: LDO pressure control drive card LO-11 valve failed causing local bus failure hence O2, Air flow,
fuel flow, fuel master got magenta on PMS hence P.A. through running mill got reduced to 30% causing air
flow reduction hence Boiler Pressure drastically dropped.
Turbine EHC control change over to pressure control hence load dropped from 500MW to 450 to
235 to 35 MW hence sliding pressure set point reduced below actual HRH pressure hence LP Bypass opened
100% hence turbine tripped on condenser vacuum very low (condenser pressure very high) and boiler tripped
on drum valve very low protection. S.O.E.-I Attached.
Work Carried Out: I&C-II section: On Dt.04: 04:2006 at 13:49 hrs Total Air flow, O2 in flue gas, Total flue
flow and other parameters in station No.4.09 of panel CRA-02 become invalid.
Failure of Total fuel flow, Total airflow signals caused Boiler Master Control and CMC to shift to
manual and fuel demand (air flow set point for P.A. through mill) to mills become zero. P.A. through mill
dampers of all coal mills was on auto and hence started closing and mills got unloaded. Main steam pressure
reduced below set point by more than 8 Kg/cm2 and Turbine EHC control shifted to pressure controller.
Pressure controller unloaded Turbine to maintain pressure. Reduction in load resulted in reduction in sliding
pressure set point of LP bypass control valves opened fully on auto and vacuum in condenser dropped.
Turbine tripped on Condenser vacuum very low protection At 13:53:53 Hrs and Followed by
Generator tripping. Due to large fluctuations in load, Boiler tripped on Drum level very low protection.
On checking, local bus data transmission found stopped. Supply of 24 VDC from both sources
found intact. Control cards were pulled out one by one to locate faulty card. On removing Drive control card
(Type As-06) of light pressure control valve. Bus fault resetted. The card was noticed to be abnormally hot,
field wiring to card was checked for earthing and short circuiting and found O.K. New spare card was put in
service and in service and is working normally.
TM-II / EM-II / BM-II / TEST-II section: No work carried out.
Recommendations:
Short Term:AS 06 drive card replace and system made normal.
Long Term: Matter referred to BHEL Banglore.
Remark: S.E. (E) II Critical panel should be provided with additional cooling arrangement.
S.E. (O) - II 1) Circular No. 2826 dt. 23/05/2006 issued to PCR operation staff above closing of
BFP spray isolating valves.
2) Passing valve will be attended in O/H of unit 7.
-----0-----
EVENT ANALYSIS
UNIT NO: 7
Event no: M3/2006
Date: 09/05/2006
Time: 17:28 Hrs
Load: 450 MW
Coal cycle in service: AB, CD, EF, (GH) with H feeder
Oil Support: Nil
Description: Seal air fan TG tripped on master tripped relay operated, before tripping current was 163 Amp
and dish press 1646 mmWCl, seal air fan 7H pick up on auto.
Window Indication appeared / Relay operated: NIL
Boiler Light up:
Time --:-- Hrs
Date --/--/----
TG set synchronisation: Time --:-- Hrs
Date --/--/----
Problem faced during bringing back the set on bar: NIL

Analysis: 1) Seal air fan TG tripped on master trip relay operation, at local panel motor tripped on
instantaneous over current with 20 times current of R & B phase as per TEST-II.
2) As per EM-II after motor feeder checking motor J.B. terminal found burnt.
Work Carried Out:
EM-II section: 1). Power cable at motor TB found heated up, heated cable removed & same is terminated in
intermediate JB & JB to motor TB copper flexible cable provided.
2). Power contractor contacts found blackened due to chattering it is replaced.
3). Motor leads found shortened due to melting, motor replaced by spare one.
TM-II / BM-II / I&C-II / TEST-II section: No work carried out.
Recommendations:
Short Term: As above.
Long Term: Aluminum cable 2 X 180 mm 2 is brought at motor TB due to which termination at TB is very
congested. To avoid this intermediate JB near motor is inserted & 95 mm 2 copper flexible provided to avoid
any looseness in motor terminal box.
Remark: SE (E) II 1) Intermediate J.B. should be provided to all seal air fan.
2) Noted all seal air fan will be provided intermediate JB one by one.
-----0-----
EVENT ANALYSIS
UNIT NO: 7
Event no: M5/2006
Date: 12/05/2006
Time: 15:22 Hrs
Load: 486 MW
Coal cycle in service: AB, CD, EF, JK
Oil Support: Nil
Description: Load dropped from 486 MW to 440 MW due to tripping of coal mill 7EF causing heating in
main turbine EHG hence load variation from 440 MW to zero MW, HP by pass opened on auto both TDBFP
running came on hydraulic mode.
Boiler Light up:
Time --: -- Hrs
Date --/--/----
Time --: -- Hrs
Date --/--/----

Analysis: 1) C/M-7EF tripped on reduced lub oil flow low, its reducer LOP No-1 was I/S it tripped on low
flow due to filter chockup, reducer LOP-II pickup on auto mode but luboil flow low at resetted hence C/M7EF tripped on mill lubrication not O.K.
2) Main turbine EHG hunting started causing load variation from 440 MW to zero MW four, five times. Both
TDBFP came on hydraulic mode due to load variation. Immediately main turbine taken on hydraulic Mode
load stabilized at 380-400 MW, TDBFP put on EHG one by one & load increased to 440 MW
3) C/M-7EF reducer lub oil both filters cleaned, it has frequent chock up tendency, metallic particles observed
in filter, C/M-7EF was taken I/S at 18=19 again Coal mill 7EF tripped on mill lubrication not OK. At 19:34
Hrs. EHG hunting trend & event log attached herewith.
Work carried Out: Turbine control shifted to Hydraulic mode as hunting was observed in EHC. EHC
isolated by closing I/L & O/L valves. EHC plunger coil removed for checking. Support insulation of EHC coil
connections found damaged and small pieces of insulating material found entered in pilot spool assembly.
Operation of spool became jerky due to entry of foreign material and made EHC to hunt. EHC plunger coil
replaced by spare coil, and EHC pilot cleaned by TM-II Governing characteristics noted with replaced coil
and turbine control shifted to EHC mode. It is planned to carry out physical inspection of EHC coil during
each annual overhaul to avoid recurrence of such problem.
Recommendations:
Short Term: Nil
Long Term:
1) It is planned to carried out physical inspection of EHC coil during each annual overhaul.
2) Matter regarding modifying insulating material is refferd to OEM. Work letter enclosed for approval.
Remark: GM-II 1) What is the analysis of failure of support insulating material?
2) What remedial measures are proposed?
a) Change of material.
b) Cooling arrangement.
c) Any other method.
EE (I & C) -II 1. Reason for failure of support insulation may be the aging effect.
2. Remedial measures.
a) Regarding change of insulation material we may write to OEM m/s. BHEL.
b) Cooling arrangement is not required, as temp of inside of EHC is not more than
700C.
c) In case of coil failure it should be replaced by new one supplied by OEM.
-----0-----
10
EVENT ANALYSIS
UNIT NO: 7
Event no: 03/2006
Date: 13/06/2006
Time: 04:58 Hrs
Load: 500 MW
Coal cycle in service: AB, CD, GH, JK
Oil Support: Nil
Description: At 04:36 Hrs. TDBFP-7A & 7B suction flow increased from 890 T/Hr. to 960 T/Hr.Feed flow
increased from 1561 T/Hr. to 1685 T/Hr. flue gas temp (RHS) started dropping from 962 0C to 750 0C & DM
make up increased upto 100 tons & then to 340 tons with emergency make up in service. Tube leakage sound
noticed at 53 Mtrs. Near divisional panel towards Unit 6 side. At 4:58 Hrs. unit handtripped.
Boiler Light up:
Time 02:03 Hrs
Date 15/06/2006
Time 08:27 Hrs
Date 15/06/2006

Analysis: Primary leakage near LRSB 123 at 53 Mtr elevations Front Reheater coil no. 40 one bend tube
cracked. Secondary damage in water wall rear arch one no.tube burst open two no. tubes found eroded.
Work carried out: BM-II section:
1) Front bend of ckt. No. 40,30 & 44 replaced due to five cracks. (Primary failure)
1) Rear arch W/W bend no.120, 121 & 122 replaced (Secondary failure)
Recommendations:
Short Term: All damaged bends replaced & leaky bend detected during air leak test are replaced.
Long Term:
2) During AOH all bends in SS 347 H material will be checked by U.T. & damaged bends will be replaced.
3) All bends (front) in front Reheater (CKT No.1) will be replaced during overhaul in 2007.
Remark:
GM-II: Nil.
-----0-----
11
EVENT ANALYSIS
UNIT NO: 7
Event no: 04/2006
Date: 15/06/2006
Time: 09:13 Hrs
Load: 129 MW
Coal cycle in service: AB
Oil Support: AB, CD, EF
Description: Unit tripped on Generator overall differential protection. Fire observed above Generator casing
at turbine end (GTR side), Turbine tripped. Boiler tripped on Flame failure.
Window Indication appeared / Relay operated: A) Indication on PMS- a) AVR fault,
B) Gen.7 master trip group 2 operated.
C) Gen TRF7 Overall differential relay 87 G operated.
D) Gen. 7 differential relay 87 G operated. E) Gen. Protection inlet tripped. (SOE already submitted)
Boiler Light up:
Time --:-- Hrs
Date --/2006
TG set synchronisation: Time 10:29Hrs
Date 20/10/2006
N/A
Analysis: --Work Carried Out:

I&C-II section: 1) Overhaul related work are in progress.
2) Trends as per the requirements are handed over to the higher officer.
TM-II section: All four hydrogen coolers hydraulic test was carried out and found OK. One cooler on PCR
side towards generator is observed leak and fins damage, it is replaced by spare cooler available.
Generator both side bearing checked found OK in ultrasonic testing. Oil clearance and top oil clearance
adjusted as per design value. Both side seal bearing checked found OK in ultrasonic testing, seal bearing
rubber cord replaced.
Both side oil catcher fins replaced and design clearance adjusted.
Generator rotor fully carried out & coupling done.
Generator air leak test carried out i.e. no drop observed.
Generator seal oil system airside and hydrogen side both DPR servicing & adjustment work carried out.
BM-II / TEST-II Section: No work carried out.
12
EM-II section: Damages observed after opening of Generator:1) Primary water outlet header found badly damaged at 3 Oclock and 7 Oclock position.
2) Insulation of overhang portion found deep grove at 3 Oclock position.
3) Hollow conductors of 32 (top), 4 (bottom) bars found damaged.
4) Water box top nipples found damaged from seven locations.
Corrective action taken to rectify the damages.
1) Primary water outlet header replaced by new one (Turbine end).
2) Insulation block prepared and mounted at damaged overhang portion.
3) Bar no. 32 (top) , 4 (bottom) hollow conductors are covered with copper jackets by brazing work.
4) Water box top nipples replaced at 7 locations.
5) 6 no. HV Generator bushings replaced with new one.
Recommendations:
Short Term: --Long Term: 1) whenever liquid is found in LLD, it should be analyze for same.
2) In case of cooler leaks, M/S should be withdrawn and cooling tube plugging to be carried out.
Remark:
GM-II: ---
13
EVENT ANALYSIS
UNIT NO: 7
Event no: M6/2006
Date: 14.07.2006
Time: 09:02 Hrs
Load: --
Coal cycle in service:
Oil Support: Nil
Description: Station transformer 5 tripped with station transformer5 trouble indication on UCP.
Window Indication appeared / Relay operated:
PMS Indication on
ST5 220V DC failed.

ST-5 220V DC not failed.
ST-5 oil temp. alarm STG1 operated.
Relays operated Station 5 Master trip 86,Aux relay 86x & oil temp. alarm 300c.
Indication at GCR-
1) DMTL over current trip.

2) Oil temp. alarm.
3) Comp start Relay MTR operated.
Boiler Light up:
Time --:-- Hrs
Date /2006
Date /2006

Analysis: Station transformer no 5 tripped during changeover operation of 220V DC supply. Master trip relay
86 ST operated on protection panel & Stn Xmer back up O/C protection relay operated indication appeared in
GCR. Back up O/C relay of Y phase found maloperated during changeover trial of 220V DC supply of S tn Xmer
protection panel.
Work Carried Out: TEST-II section: 1. Faulty back up O/C protection replaced by spares one. New relay
tested & found ok. 220V DC supply changeover trial taken and found normal.
2. All other relays of station transformer protection panel are checked and normal.
3. Station transformer routine tests eg. Ratio, magnetizing current, winding resistance,IR etc. carried out.
4.Back up O/C relay operated annunciation checked in SOE& GCR & found ok.
EM-II section: Preventive maintenance is in progress.
BM-II / TM-II / TEST-II section: No work carried out.
Recommendations:
Short Term: -Long Term: -Remark:
GM-II: -POG/VARIOUS REPORT/EVENT ANALYSIS
14
EVENT ANALYSIS
UNIT NO: 7
Event no: M7/2006
Date: 31.08.2006
Time: 09:19 Hrs.
Load: --
Coal cycle in service:--
Oil Support: Nil
Description: Station X mer No.5 tripped with Earth Fault and MTR Trip indication in GCR.(Lighting X
mer
LXC1-H.T. side Bushing flexible link burnt, due to movement of rat inside panel causing earth fault.)
Window Indication appeared / Relay operated: 1) Stn.5 Trouble.
2) Stn. SWGR SG 11/1-incomer trip.
3) LXC-1 trouble.
4) 220V D.C battery/charger trouble.
5) 24V DC battery /charger trouble.
Relay operated 1) 86,86X
2) Aux.spare 30GHJ Marshalling box supply failed.
3) Aux rest-Earth fault L.V. side 64 Lx.
Boiler Light up:
Time
Hrs
Date /2006
TG set synchronisation: Time
Hrs
Date /2006
Problem faced during bringing back the set on bar: LXC.1 lighting X mer-1 isolated electrically and Stn.
X mer5 charged again and electrical circuit / boards normalized.
Analysis: All openings of panels / breakers to be sealed properly.
Work Carried Out: Test-II section -The tripping of Stn. X mer is spurious as the fault occurred out of zone.
Due to malfunctioning of REF relay. Also, there are several incidences of similar nature occurred in past. The
Matter referred with OEM and H.O. many a times but no clarification corrective received till date.
EM-II section: R-phase lug sat bushing end found burnt due to foreign material .The same is replaced by new
lugset and transformer charged.
BM-II / TM-II / I&C-II section: No work carried out.
Recommendations:
Short Term: Door locking & hole sealing is done properly.
Long Term: Arrangement for proper door locking &hole sealing for all dry type transformer will be ensured.
Recommended for closing the Xmer room. Note is being sent to operation.
Remark:
GM-II: Matter of spurious tripping already taken up with m/s ABB. They shall be carry up with work plan by
25/11/06 Matter of spurious operation of REF should be taken up to OEM.
15
EVENT ANALYSIS
UNIT NO:7
Event no: 05/2006
Date: 22.10.2006
Time: 16:00 Hrs.
Load: 72 M
Coal cycle in service:--
Oil Support:--
Description: Unit withdrawn due to abnormal rise in temp. of Generator stator top bar no.32 (Repaired bar).
Boiler Light up:
Time 01:26 Hrs
Date 28/10 /2006
TG set synchronisation: Time 14: 48 Hrs
Date 28/10 /2006
N/A
Analysis: N/A
Work Carried Out: I&C Section: Resistance of P.W bar temp. RTD top bar no. T-32 Upper checked in
locale J.B and panel end and correct as per temp. shown (1600C). Resistance 164 ohm =1600C .Behavior of
RTD was erratic, hence unit withdrawn.
After unit withdrawn, T-32 lead wires came out from RTD, M/S BHEL Haridwar team brought new 7
RTDs. During checking, 3 RTDs. found faulty. Hence 4 new RTDs and 2 RTDs recovered from old P.W
header was installed on P.W bar T-37, B-45, T-45, T-30 and T-32, by BHEL. RTDs of T-37, B-45, T-45, T-30
and T-32 were also showing erratic behavior before withdrawn of unit.
EM-II Section 1) Thermal chalk marks on all repaired bars were checked and found intack. Temp. of P.W.
of repaired bar dont exceed the permissible limit while checking.
2) Bar T-32 header end Teflon hose removed and flushing N2 through stator bar for checking any chock up
inside it. Before flushing by N2, outlet primary water header was made dummy at position where T-32 bar is
connected by Teflon hose .N2 gas flow was normal during flushing of stator bar.
3) Air leak test of generator stator at 5Kg/cm2 is carried out to ascertain any leakages through manholes
which were opened for inspection .No leakages observed .4) Generator stator flushed with N2 gas.
BM-II / TM-II / TEST-II section No work carried out.
Recommendations:
Short Term:
Long Term:OEM, M/S BHEL is informed about quality. Hence after every RTD for these measurements
shall be checked thoroughly.
Remark:
GM-II: -POG/VARIOUS REPORT/EVENT ANALYSIS
16
EVENT ANALYSIS
UNIT NO: 7
Event no: 06/2006
Date: 30/10/2006
Time: 10:48 Hrs
Load: 370 MW
Oil Support: Nil
Description: TD BFP 7A tripped on thrust pad bearing temp very high (158 0C) on 370 MW load at 10:35 hrs.
HPCV-1 position observed 8.58% with sec. oil pressure 4.02 kg/cm 2 and HPCV-2 position observed 6.69%
with sec. oil pressure same 4.02 kg/cm2 pertaining to EHC-1 position 44.65%, load reduced to 260 MW. C/MEF & GH hand tripped. Unit was hand tripped due to steam leakage near HP turbine through Breech nut.
1) Gland steam pressure abnormal.
2) Shaft vibration high.
3) Gen. RPP operated.
4) Gen. Maths tripped operated.
5) Gen. Protection operated.
6) Gen. 7 PT fan fail.
7) Boiler tripped on RH protection.
8) MOT level low.
9) Speed slope low.
Boiler Light up:
Time 13:20Hrs
Date 30/10/2006
Date 30/10/2006
N/A
Analysis: N/A
Work Carried Out: I&C-II section: TDBFP 7A DE side bearing out leakage attended. Mechanical seal
cooler ACW line filtering done and cooler cleaned.Due to sharp drop of BEF ESV main steam temp from
506.840 C to 420.90 C. steam leakage found from both Breech nut is developed.
TM-II section: TDBFP-7A main pump thrust bearing working pad both RTD found faulty.
BM-II / TEST-II / EM-II section: No work carried out.
Recommendations:
Short Term: S/H steam temp control valves should maintain steam temp as per set point on auto. Necessary
calibration / tuning to be done.
Long Term: 1) RTDs shall be fitted only after thorough checking.
Remark:
GM-II: Sharp temp variations in MS / RH steam should be avoided while lad variation care to be taken.
17
EVENT ANALYSIS
UNIT NO: 7
Event no: M8/2006
Date: 01/11/2006
Time: 14:00 Hrs
Load: 450 MW
Oil Support: Nil
Description: TSC higher margin for turbine loading in maintaining less than 5.
1) M.S. temp =5250 C
2) HP outer casing temp100%=5250 C
3) HP outer casing temp 50%=4870 C.
4) HP outer casing top mid 50%(DT>100)-4880 C.
5) HP casing top mid 50% (DT>100)-4850C. 6) HP outer casing in SEC MET TM-5090C.
Window Indication appeared / Relay operated: N/A
Boiler Light up:
Time --: -- Hrs
Date --/--/----
TG set synchronisation: Time --: -- Hrs
Date --/--/----
N/A
Analysis: N/A
Work Carried Out: I&C-II section: HPC temp at 50% depth and 100% depth thermocouples connected in
TSC circuit found faulty due to high junction resistance.
100 % element replaced with new spare, 50% element could not be removed hence spare element of
30% top thermocouple in turbine trip circuit connected in TSC circuit top margin of HPC is now above 300 C.
BM-II / TM-II / TEST-II section: No work carried out.
Recommendations:
Short Term: --Long Term: 1) Metal temp thermocouple shall be replaced with new ones procured from OEM (i.e. BHEL
during capital overhaul.
2) Only tested & calibrated thermocouple shall be used.
Remark:
GM-II: ---
18
EVENT ANALYSIS
UNIT NO: 7
Event no: M10/2006
Date: 01/11/2006
Time: 14:50 Hrs
Load: 450 MW
Oil Support: Nil
Description: TG set Shaft vibrations are maintaining high(with reference to old reading)
Load-450 MW
Bearing 1-61
Load-499 MW
Bearing 1-50
Bearing 2-75
Bearing 2-24
Bearing 3- 49
Bearing 3-13
Bearing 4-81
Bearing 4-30.9
Bearing 5-73
Bearing 5-53
Bearing 7-73
Bearing 7-54.4

Boiler Light up:
Time --: -- Hrs
Date --/--/----
Date --/--/----
N/A
Analysis: N/A
Work Carried Out: TM-II section: Regarding high vibration, letter no 4352 D/02 Nov 2006, send to BHEL
Nagpur for solution. But reply of BHEL dated 04/11/06 said vibration is in limit. Vibration is monitored
regularly.
Recommendations:
Short Term: --Long Term: --Remark:
Sr EE / SE (M): Matter refered to BHEL for analysis and corrective action.
S E (E): Vibrations are cross-checked by I&C staff & readings submitted to SE- (M-II) on 4/11/06. From cross
checking it is confirmed that vibration carrying by staff is OK.
GM-II: ---
19
EVENT ANALYSIS
UNIT NO: 7
Event no: 07/2006
Date: 06/11/2006
Time: 15:37 Hrs
Load: 440 MW
Oil Support: Nil
Description: TG set tripped at 15:37 Hrs due to failure of 24V control supply on Gen protection operated.
Boiler tripped on Loss of all fuel. Smoke observed from G2 battery charger.
1) Gen protection operated.
2) Gen. Breaker operated.
3) EHC fault.
4) Turbine trip.
5) Boiler fire off.
6) MFT operated.
Boiler Light up:
Time 18:44Hrs
Date 06/11/2006
Date 06/11/2006

1). TG set not synchronized manually as synchronizer not getting ON.
2). C/M CD tripped on lub oil not OK.
3).O/S in EF elevation not proved.
Analysis: G2 battery charger filter choke burnt.
Work Carried Out: EM-II section: 1) 2000 A filter choke isolated.
2) Common negative earthing at 0 meter level dry type transformer room found heated and dislodged from
the earthing electrode, same is restored.
4) 4 failed thyrister, 6 blown-off fuses are replaced before the detail investigation carried out.
Then the load trial upto500 Amp are taken for 4 hours and found OK. Charger cleared for
services.
I&C-II section: Due to failure of 24V DC supply from sources G1 & G2 to DDC panel CRA-05 (covering
PA hydropressure control and co-ordinated master control) IGVS of both PA fans closed (Demand signal
became zero). Coal mills tripped on PA header pressure very low protections and since oil elevation was not
in service, Boiler tripped on Loss of all fuel protection.
Turbine tripped on Boiler OFF, & Generator on Reverse power protection.
20
Abnormalities found during consequent checking:

1) 32 Amp rating fuses of following feeders on G1 distribution board found blown.
a) DDC panel: CRA-03, CRA-05, CRB-01, CRB-04, CRC-02, CRC-05.
2) Pro-control card in following panel found faulty during restoration
i)Panel CRB-02 3 Nos Binary I/P cards.
ii) Panel CRB-02/044 Nos Binary I/P cards.
iii) Panel CJJ-02AFU-11-1 & AFU-12-1,1 No each.
iv) Panel CJJ-09Surge suppressor 1 No.
v) CCA-03Binary O/P cards 2 No.
vi) Diagnostic panelBK-03 1 No.
All cards except surge suppressor in panel CJJ-09 replaced from spare. Failure of cards was
due to high value fault current flowing through cards.
Recommendations:
Short Term: Filter choke will be replaced within a week.
Long Term: 4 No split A/Cs are being provided for cooling of the charger panel.
Remark:
SE(E): G2 charger after replacement of choke is taken on 21/11/06. Parameters should be watched carefully
for the same.
GM-II: All charger should be checked periodically include in PM.
21
EVENT ANALYSIS
UNIT NO: 7
Event no: 08/2006
Date: 11/11/2006
Time: 22:16 hrs
Load: 480 MW
Oil Support: Nil
Description: TG set withdrawn at 22:16 hrs on date 11/11/2006 due to boiler tube leakage in LTSH zone.
TG set hand tripped & boiler tripped on Reheater protection.
Boiler Light up:
Time 14:50Hrs
Date 13/11/2006
Date 14/11/2006
N/A
Analysis: Evidence of primary failure is destroyed due to severe secondary damage. Failure appears due to
leakage from erection welding joint. (BHEL report attached.)
Work Carried Out: BM-II section: In LTSH inlet zone-1) Coil no.40-tube no.1 found burst open at erection
welding joint opposite to flue gas flow and tube found crack in 200mm length (Primary failure) and Tube no.2
found punctured near erection welding joint-4 no. of joints.
Secondary Failure :
2) Coil no.39- a) Tube no1 found burst open at welding joint-8 no of joints.
b) Tube no. 2 found punctured.
c) Tube no 3 & 4 found eroded.
3) Coil no.38- Tube no. 2 found eroded-2 no. of joints.
4) Coil no.41-Tube no.1 found burst open at welding joint-2 no. of joints.
5) Coil no.42- a) Tube no. 2 & 3 found punctured-8 no. of joints.
b) Tube no. 1 & 4 found eroded.
6) Coil no. 43-Tube no.2 found eroded-2 no of joints.
Recommendations:
Short Term: Radiography of coil no 37 & 44 (6 joints) taken for checking healthiness of joints. Radiography
of these joints found OK.
Long Term: --Remark:
SE(M-II): Acknowledge the correction done by (BM-II) and also see BHEL report.
GM-II: --POG/VARIOUS REPORT/EVENT ANALYSIS
22
EVENT ANALYSIS
UNIT NO: 7
Event no: M11/2006
Date: 14/11/2006 (20/10/2006,28/10/2006,30/10/2006,06/11/2006)
Time: -Load: --
Coal cycle in service: --
Oil Support: Taken
Description: While Turbine rolling from 360 rpm to 3000 rpm, Turbine tripped most of the time on DN/DT
protection. DN/DT protection needs to be bypassed to achieve 3000 rpm. Need detail analysis.
Boiler Light up:
Time --: -- Hrs
Date --/--/----
Date --/--/----
N/A
Analysis: N/A
Work Carried Out: BM-II section: Software program of DN/DT monitoring in processor of pond CJJ-07
checked and all settings found correct as per OEM recommendations.
Recommendations:
Sr EE: Matter taken up with M/S BHEL.
SE(E): This tripping is occuring because of slow down of acceleration which need to be analyzed?
Tripping is takes place as per the protection scheme.
GM-II: With rated parameters, this problem can be minimized.
23
EVENT ANALYSIS
UNIT NO: 7
Event no: 09/2006
Date: 20/11/2006
Time: 16:12 hrs
Load: 248 MW
Oil Support: Nil
Description: TA set withdrawn due t Boiler tube leakage in Economizer zone. TA set hand tripped and Boiler
tripped on Reheater protection.
Boiler Light up:
Time 21:43Hrs
Date 22/11/2006
Date 23/11/2006

Analysis: 20 mm longitudinal crack on ID of tube opened up to 3mm hole on OD from visual inspection,
failure appears due to corrosion.
Work Carried Out:
BM-II section: 1) In upper Economizer zone-Coil no. 56-(Primary failure) Fine
longitudinal crack observed in tube no.12 between hanger tube no. 2 & 3near shop welding joint opposite to
flue gas flow, (sec failure) Tube no.13 found punctured-4 no. of joints.
Secondary failure:
2) Coil no. 57: a) Tube no. 13 found thin lip opened-8 no. of joints.
b) Tube no. 14,15, 16 found eroded.
3) Assembly no 28: End connection for approach-16 no. of joints.
4) Assembly no. 29: End connection for approach-16 no. of joints.
TM-II section: LPT rotor balancing done. LP front and rear 270 gm wt added at angle 3150 Cand 450 C
respectively. LPT gland box centering done.
I&C-II section: SOE attached and work done as per the shutdown defects carried out.
Recommendations:
Short Term: Failed tube is send to M/S BHEL & metallurgical lab mumbai for detailed analysis.
Long Term: PO is placed for Economiser upper coils. Economiser (Upper) coils will be replaced during next
off.
Remark:
GM-II: --POG/VARIOUS REPORT/EVENT ANALYSIS
24
EVENT ANALYSIS
UNIT NO: 7
Event no: 10/2006
Date: 23/11/2006
Time: 23:03 Hrs
Load: 52 MW
Oil Support: AB
Description: Unit withdrawn for balancing of turbine due to high shaft/ bearing pedestal vibration. (19/11/06
at 13:45 hrs, due to sudden rise of shaft and bearing pedestal vibration to 155/43 micron. Load reduce to 350
MW from 450 MW keeping close watch on these parameters.)
Window Indication appeared / Relay operated: Boiler tripped on R/H protection after tripping of TG set.
Boiler Light up:
Time 23:31Hrs
Date 23/11/2006
Date 24/11/2006
N/A
Analysis: -Work Carried Out: TM-II section: LPT rotor balancing done 270 gm wt added at LPT front and rear. LPT
rear gland box clearance adjusted.
I&C-II section: Pedestal vibration pick-up of bearing no-4 on date 14/11/06 and bearing no-2 on 26/11/06
replaced from spares as there was hunting in readings are steady after replacement.
Recommendations:
Sr. EE / SE(M): The problem is being further analyzed by R&D BHEL upgraded. Corrective action
suggested shall be inflemented to bring the vibration level to minimum.
GM-II: --
25
EVENT ANALYSIS
UNIT NO: 7
Event no: M12/2006
Date: 24/11/2006
Time: 21:42 Hrs
Load: 158 MW
Coal cycle in service: AB, CD
Oil Support: AB-3/CD-2
Description: RCF F taken into service at 21:42 hrs, but it tripped on Tachogenerator immediately. On
checking, feeder inlet pipe found hot, so feeder inlet gate closed immediately after opening feeder cover, belt
found burnt and hot coal with smoke in feeder.
Boiler Light up:
Time --: -- Hrs
Date --/--/----
Date --/--/----
N/A
Analysis: Feeder belt burnt due to hot coal on belt.

Work Carried Out: BM-II section: No-1 Belt replaced by new one and all support rodless bearing replaced
by new. All preventive maintenance work is carried out.
Recommendations:
Short Term: Whenever Mill is standby or under maintenance for more than 2 days. Periodically checking of
feeder inlet pipe should be carryout. If inlet pipe found hot, then carryout the feeder inlet pipe . If inlet pipe
found hot, then feeder inlet gate should be closed immediately and feeder belt should be empty by running the
feeder from local. Also CHP staff must be informed to PCR staff about bunker fire to prevent, such type of
incidence.
Circular no. 4576 dated 26/12/06 drawn.
GM-II: --
26
EVENT ANALYSIS
UNIT NO: 7
Event no: M13/2006
Date: 28/11/2006
Time: 18:44 Hrs
Load: 465 MW
Oil Support: Nil
Description: At 18:44 Hrs, TG desk CRT-41 & 43 turned magenta. Server CHP-030 communication failed
and after 10 min change over to CHP-040.
Boiler Light up:
Time --: -- Hrs
Date --/--/----
Date --/--/----
N/A
Analysis: --Work Carried Out:

I&C-II section: CHP 030 server failed due failure of fixed RAM. This was diagonised after retrieving SYS
error log files on Lap-top computer by M/S HP Compaq representative. Fixed RAM memory should only 64
MB size as against 192 MB. Memory replaced under AMC and server booted. Server is functioning normal in
standby mode since 08/12/06. Trial in Master mode is taken on 20/12/2006 and found OK.
Recommendations:
GM-II: ---
27
EVENT ANALYSIS
UNIT NO: 7
Event no: M14/2006
Date: 02/12/2006
Time: 10:06 Hrs
Load: 410 MW
Oil Support: Nil
Description: At 10:06 Hrs, PRDS pressure and temp. got raised from 11.82 kg/m 2 / 1950C to 19.48 kg/cm2 /
3500C with LC line CV ASP-08 I/S. Safety valve started floating. No variation in LC CV observed. PRDS
pressure was 12.2 kg/cm2 and temp set point was 2200C .
Boiler Light up:
Time --: -- Hrs
Date --/--/----
Date --/--/----
N/A
Analysis: HC line CV ASP-05 and motorised isolating valve and ASP-04 and ASP-06 opened to full from 0%
and suddenly PMS pressure raised to 19 kg/cm2 .
Work Carried Out: I&C-II section: Auto open command on position feedback >=2% (i.e. more than 2%
open) of control valve ASP-05 provided to motorised isolating valves ASP-04 and ASP-06 alongwith their
IBVS in original scheme. Similar interlock was also provided to motorised valves ASP-01, ASP-03 on
position of ASP-02 control valve.
Auto open/close commands to isolating motorized valves defeated vide EP No-21307 dated
02/12/06as per the requirement to avoid recurrence. Motorised valve ASP-01, 03, 04 and ASP-06 will now
open or close on only Manual command.
Recommendations:
GM-II: ---
28
EVENT ANALYSIS
UNIT NO: 7
Event no: M15/2006
Date: 11/12/2006
Time: 08:17 Hrs
Load: 475 MW
Coal cycle in service: AB, EF, GH , JK
Oil Support: Nil
Description: Upper bar PW temp T-39 increased upto 1060C gradually. Load reduced upto 450 MW from 475
MW and temp started at reducing from 1060C to 720C. Temp varies as per load variation.
Boiler Light up:
Time --:-- Hrs
Date --/2006
Date --/2006
N/A
Analysis: --Work Carried Out: I&C-II section: Resistance of RTD for T-39 bar checked a panel end on 11/12/2006
vide EP No-48413 after isolating from card. Resistance was 127 which correspond to 69 0C and PM6 reading
was 700C.Further checking will be done in Unit shutdown.
Recommendations:
Short Term: Temp is showing as per RTD resistance. RTD checking shall be carried out in next available
opportunity when RTD can be occurred through manhole of the generator.
SE(O): At present temp is maintaining but its winding / RTD should be checked in next shutdown.
GM-II: ---
29
EVENT ANALYSIS
UNIT NO: 7
Event no: M16/2006
Date: 14/12/2006
Time: 06:46 Hrs
Load: 445 MW
Coal cycle in service: CD, EF, GH, JK
Oil Support: Nil
Description: Seal oil temp after cooler short upto 65 0 C and again became normal.
Window Indication appeared / Relay operated: Trip signal deviation indication appeal on UCP.
Boiler Light up:
Time --:-- Hrs
Date --/2006
Date --/2006
N/A
Analysis: --Work Carried Out: I&C-II section: Seal oil temp. RTDs MKW71FT002A and MKWZ1FT003A are used in
measuring SO temp after cooler and tripping is provided if both temp exceed 600C.
RTD MKW71 FT002Ais showing sudden variations. Tightened the RTD variation on head and JB no.
variation observed since temp shown are 460C. to 410C. RTD checking and analog conditioning card will be
done in next unit-5. Trip signal deviation indication appeared due to difference in two RTDs.
Recommendations:
Short Term: Tightened the connections in local JB and RTD head.
Long Term: RTD checking and signal conditioning card calibration will be done in next unit shutdown.
Remark:
GM-II: --
30
EVENT ANALYSIS
UNIT NO: 7
Event no: M17/2006
Date: 12/12/2006
Time: 16:50 Hrs
Load: 455 MW
Oil Support: Nil
Description: As per the vibration analysis report on date 12/12/2006 at 16:50 hr * rpm components appear
at bearing no. 1 to 5 which indicates rubbing phenomena. Also at bearing no. 4 3* rpm velocity level has
increased substantially, running in unsatisfactory zone. Problem needs to be attended on top priority.
Window Indication appeared / Relay operated: Vibration readings collected 3 cam(TIC) shaft on dated
14/12/2006 at 13:20 hrs enclosed herewith.
Boiler Light up:
Time --:-- Hrs
Date --/2006
Date --/2006
N/A
Analysis: --Work Carried Out: TM-II section: Letter send to BHEL to analyse the problem and suggest corrective
action at the earliest
Recommendations:
Short Term: Increase the lub oil temp by 10C.
SE(O) : Please arrange to check turbine bearing no. 4 as well as its probe in shutdown if possible.
GM-II: ---
31

Event Ana U#7,2006 - Completed

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Unit-7

Water wall tube leakage at corner no. 3

No indication Liquid in Gen. high on CPU and on PMS.

Load variation from 440 to zero MW C/M-EF tripped.

Front Reheater tube leakage.

T-G set shaft vibrations are maintaining high.

Boiler tripped on Loss of all fuel DDC panel 24 V DC

LTSH Inlet header tube leakage.

Turbine tripped on DN/DT protection on last five

Economizer (Upper) tube leakage.

T-G Desk CRT-G1 & G3 turned magenta.

PRDS pressure & temp. increased suddenly & safety valves

Generator Stator Upper Bar T-39 PW outlet temp. high.

POG/VARIOUS REPORT/EVENT ANALYSIS

T-A set tripped on Condenser vacuum very low protection.

Set tripped on Gen. Overall differential protection. Fire

Set w/d for turbine balancing due to shaft/ bearing pedestal

Coal cycle in service: AB, CD, EF, GH

Oil Support: Nil

Time 22:59 Hrs

TG set synchronisation: Time 07:22 Hrs

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD, EF, JK

Oil Support: Nil

Time ---- Hrs

TG set synchronisation: Time ---- Hrs

Problem faced during bringing back the set on bar: Nil

Liquid in Gen. Turbine end

Liquid in Gen. Center

Liquid in Mains Lead Bottom-MKA23CL001

Liquid in Main Lead Bottom -MKA23CL011

Liquid in Main Lead Top

Liquid in Main Lead Top

In Healthy Condition Simultaneous Operation of Probes at Sr.No.II to V leads to Generator tripping.

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, EF, GH, JK

Oil Support: Nil

Time 14:31 Hrs

Time 11:34 Hrs

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD, EF, (GH) with H feeder

Oil Support: Nil

Time --:-- Hrs

TG set synchronisation: Time --:-- Hrs

Problem faced during bringing back the set on bar: NIL

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD, EF, JK

Oil Support: Nil

Time --: -- Hrs

Time --: -- Hrs

Problem faced during bringing back the set on bar: NIL

POG/VARIOUS REPORT/EVENT ANALYSIS

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD, GH, JK

Oil Support: Nil

Time 02:03 Hrs

Time 08:27 Hrs

Problem faced during bringing back the set on bar: NIL

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB