Commissioning Status as on 21-Nov-17.
# Unit Rtg
1 Bellary - 3 700
2 CPCL Ph-IV-Unit 5 - GT
3 Kothagudam - 12 800
Ld BLU Sync CA Status
S:27-Mar-2014 S:27-Apr-2014 S:27-May-2014
470 # Unit is running at 470 MW, coal flow 282T/Hr, Mills-CEFG in service. MDBFP and TDBFP-B in
P:1-Sep-2014 P:31-Aug-2015 P:23-Feb-2016
A:28-Mar-2015 A:25-Dec-2015 A:1-Mar-2016 service. Generation 10.65 MU.
#Load restricted to 400-500 MW due to coal shortage and LDC requirement.
#All BFPs mechanical seal temp high issue- Vendor visited site and the modification of cooling
water line inside the skid flow measurement is done. Flow measured and found as 6 LPM with
both coolers in service and with one cooler 12 LPM, whereas required design flow is 40 LPM.
Vendor left and matter taken up with BHEL/Hyderabad/PEM for resolving the issue.
#BHEL/Jhansi technician is left to Kakatiya site yesterday. Oil filtration is in progress.
#OZonization system balance work is in progress. Ozone module supply is pending for further
commissioning of system.
#Feeder-A damaged items quotation asked from M/s Merrick. It is informed to KPCL for insurance
lodging.
#Mill-B one of the roller (J3) got jammed and rectification work is in progress.
#Once again MDBFP oil flashing is observed at >4500 rpm and matter referred to HYD for deploy
of engineer to resolve the issue.
#Clarified pump house transformer-1 and switchyard transformer-1 cable found damaged during
last flash over. The same being replaced and matter taken up with PEM for supply and quality
issue.
S:- S:- S:-
20 0 # Diverter Damper and Guillotine Gate JB erection completed, cabling and termination
P:30-Sep-2017 P:30-Sep-2017 P:30-Sep-2017
A:- A:- A:- completed.Vendor called to reach site on 22.11.17
# Honeywell PLC panels erection completed. Room readiness reqd for further works.
# HRSG Duct Air leak test commenced on 28.10.2017 and Identified leaks being attended. NMEJ
strips received at site on 18.11.2017.
# Calibration of skid instruments is in progress. 575/900 completed.
# DD JBs checking with local supply completed.
#UB-MP steam line internal Hydro test completed successfully.
#UPS panel charged and checking completed. Battery commissioning only after room readiness
like AC & door fixing etc (Dust proof environment)
Constraints:
# ACDB 3&4 for GT and HRSG design finalized. Manufacturing in progress.
# SRR room readiness & Earth pits for Mark VI erection.
# Gen Trf foundation and LAVT&NGR foundation, cable trench/tray readiness(Customer scope)
# NPH building to SRR building, GTG area, Common Control room and UB area Main cable
route/tray works to be completed (customer scope).
# GT MCC ,125V DCDB and other LT panels (BOILER PMCC, HRSG MCC,BOP MCC,BOILER
MCC, Aux.PDB,MLDB,110V ACDBs, and WMDBs ) defects and issues identified during testing
are to be attended by L & T and C&S respectively.The defective items removed from panel are
sent on 21.08.17 to C&S works
# Customers clearance is required for inter panel cabling from GCP, GRP, DAVR with existing
ECP. BOP MCC and HRSG MCC- customer permit is required for charging.
# Guillotine gate seal air fan A&B damaged impeller blades to be rectified by vendor. BHEL Hyd
given cost debit acceptance to be procured by site for raised CAR disposition. PO placed on
13.10.17 for new impeller blades.4 weeks supply time
# Diverter Damper electrical operation done, open torque operated at 50 % open condition.
Manual operation also taking heavy load, vendor inspection required.
# Customer permit required for testing of CTs & VCB operation of GCB ,SAT 1&2 & FD fan 6.6 KV
feeders.
0 #Lub oil flushing of ID fan B I stage is in progress since 6/11/17.
#Lub oil flusing of FD fan B Stage 1 completed on 20.11.17.Lub oil flushing Stage 2 is in progress.
#Lub oil flusing of MDBFP -C is in progress since 6/11/17.
#SAT Testing under progress
#Electrical -HT- OCA board numerical relay testing is in progress.
#ESP 1HD board testing started & is in progress. (IR & WR for CST )
#Boiler MCC 0DB & 1DB testing is in progress (CRM test).
#Seal Oil pipelines acid cleaning preparatory works under progress.
#Total 2 nos FCBC & 2 nos FC(220 VDC) commissioned. DCDB 1FA board charged.
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 S:10-Feb-2014 S:10-Jun-2014 S:10-Jul-2014
4 Muddanur - 6 600 0 # Boiler is under wet preservation.
P:9-Feb-2017 P:10-May-2017 P:23-Oct-2017
A:29-Dec-2016 A:2-Jul-2017 A:- #Mill G&H lube oil tank cleaning completed. Oil filling completed.
# DMCW system: Pump suction valves door seal received from BHEL-Bhopal. Replacement works
is in progress.
#Mill-C second stage lube oil flushing completed.
#Mill E&F stage 1 lube oil flushing declared completed. Oil draining completed.
#LRSB Dry commissioning is in progress (37/42 completed). Balance 5 LRSBs traverse motor
winding resistance problem.
# ESP A pass all fields were charged and tested(20 /20 fields are healthy), HVR 10 A2 is having
problem. ESP B pass all fields were charged(20/20 fields are healthy). ESP C pass HVR testing
completed. SC & OC tests are in progress.
# Seal oil vacuum pump cable has continuity issue, customer is solving the problem.
# Underrated HT numerical Relays replacement received from M/S Schneider. Replacement work
completed(52/52 completed).
# TDBFP A ,governing system charged and stop valve stroking has been checked.
# SV-7 Materials received at site. Safety valve technician from BHEL-Trichy is awaited for
assembly.
# Constraints : (i) Safety valve technician from BHEL Trichy.
(ii)TDBFP A DC EOP shunt field resistance is not as per datasheet. CAR raised for solution as
running speed is higher than rated speed.
S:30-Apr-2017 S:31-Jul-2017 S:31-Oct-2017
5 New Neyveli - 1 500 0 #AOP 1&2 run for 10 mins and leaks observed, are being attended. (Seal oil system isolated- seal
P:31-Dec-2017 P:31-Mar-2018 P:31-Mar-2018
A:- A:- A:- oil system permanent lines at generator end and looping to be completed).
# BHEL-Rudrapur Welder reported site and ST-1 LV bus duct IR value measure and found low.
Space heater kept on.
#FD Fan-1A stage -1 Flushing started
#FOPH MCC breaker logic checking in progress.
Auxiliary Boiler :
#FST boxed up after cleaning and inspection completed .
Constraints :
# Unit-1 EOP pump& Motor with starter panel to be supplied from - BHEL HARDWAR. Slow work
progress by TG sub-contractor M/s EDAC.
# 1 no Instrument air compressor (Atlas Copco) to be supplied by PEM. PO amendment due to
GST issue.
#Stabilizing resistor value for transformer diff, and REF protection is not given by PEM.
#CEA inspection completed on 11.10.2017. Inspection report balance works to be completed by
M/s NLC for CEA clearance.
#CEP- motor stools to be dispatched from BHEL-Hyd.(mismatch observed during erection.
#Schneider and BHEL EPD to resolve- noted IMCC logic issues in motors and valves feeders.

6 New Neyveli - 2 500 0 # MDBFP-2C stage-II oil flushing in progress

#FD-2A stag-1 lube oil flushing started
#2HD and 2TB bus bar CRM test completed, 2HD space heater circuit checking completed.
#0QB IMCC checking in progress..
#2HB control transformer testing in progress.

7 RINL - TB5 25 0 # TB#5 surge test is declared complete by M/s RINL. Surge test results are sent to M/s MDT
Germany for analysis and acceptance to carry out further operation of the blower.M/s MDT
Engineers are available at site.
# Turbine Blower -5 is on barring gear.
#MDT-BHEL hardwired signal checking from DCS completed
#Meeting was held on 18/11/17 along with M/s RINL,M/s MECON and Site staff for further
operation and Customer is insisting to complete all pending works to avoid further shutdown of
TB#5.
#Actuators status: out of 70 actuators,62 are commissioned locally. 54 actuators are made
through from Remote. 8 (2 yet to be erected IN MS line + 6 (CAR issues) Vendor engineer
needed ) actuators are to be commissioned.
# Shut down for completing Extra works in Boiler -6 and TG-5 is postponed and expected date to
be confirmed by M/s RINL.
# HP Heater-1 & 2 drip lines to deaerator Hydro test is completed. Waiting for Clearance from M/s
RINL for hook up of drip lines of HP Heater-1 & 2 to deaerator & MS header towards TB#4. For
FW line Hook up clearance is given on 06/11/17 but M/s RINL TPP Operation department raised
an issue related to design related to isolation valves position. Matter is being analysed by M/s
Mecon (Consultant).
# No Commissioning engineer is available at site from M/s S&W. Chiller plant is under
preservation. Without any information to site M/s S&W commissioning engineer left site.
S:8-Sep-2013 S:8-Jan-2014 S:1-Aug-2015
8 Yermarus - 1 800 313 # Unit is presently running at 313 MW. Load restriction is due coal availability issue (Coal feeding
P:16-Jul-2015 P:30-Oct-2015 P:29-Feb-2016
A:10-Aug-2015 A:9-Feb-2016 A:29-Mar-2016 is restricted to 4000T/day) Generation 7.39MU
# HP heater kept under warm up.
# Boiler fill pump A spare materials received from M/s. Flowmore, service engineer awaited.
# BOP : Plant AC - one chiller and 2 VAM - monsoon period PG test completed, protocol being
made.
Constraints: (i) HFO pump A not developing pressure due to contaminated oil use by RPCL.(ii) GI
pipe supply by GMW for firefighting system. (iii) M/s KOSO to supply 3 nos. of HWL plug. One
number of SS oil tank to be supplied for Unit-1. (iv) Boiler fill pump A and B shaft got sheared
and matter taken up with PEM for repair/replacement.(v) Bunker D choke, work is in progress.
# Auxiliary Boiler: Steam blowing declared completed.

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 S:8-Mar-2014 S:8-Jul-2014 S:17-Nov-2015
9 Yermarus - 2 800 0 # Boiler kept under preservation.
P:28-Jan-2016 P:16-May-2016 P:25-Jan-2017
A:25-Feb-2016 A:21-Jul-2016 A:29-Mar-2017 # Turbine generator CRO checking in progress.
# HPCV actuators sent to Rexroth, Ahmadabad. Noise problem rectification completed at works.
Another 2 actuators also to be sent to Rexroth progressively.

10 Hindalco - 1 150 151 # Unit is running at 151 MW

11 Hindalco - 2 150 150 # Unit is running at 150 MW.

12 Hindalco - 3 150 0 #Unit tripped due to switch yard problem.

13 Hindalco - 4 150 0 # Unit is under SD for standby.

14 Hindalco - 5 150 150 # Unit is running at 150 MW.

15 Hindalco - 6 150 150 # Unit is running at 150 MW

# Dearator level drop test at full load conducted, readings recorded and are being analysed.
#TG PG test parameters tuning and optimization is in progress in presence of BHEL Hyd PG test team. BHEL HYD Heaters team has left
the site.

16 Malwa - 1 600 0 # Unit was shut down on 20.11.17 at 2355hrs due to coal shortage. Generation in (MU): 7.59MU.

17 Malwa - 2 600 300 # Unit is running at 300 MW load with Fuel flow 195 TPH and Vacuum 0.062/0.060 KSC. Generation in (MU): 7.740MU.

18 NTPL Tuticorin - 1 500 289 # Unit is running at 289 MW, Coal flow 290 TPH, Cond. vacuum 0.131, Mills ACEFGH, TDBFP A&B are in service Generation : 8.64MU.
#Balance pending points - 52

19 NTPL Tuticorin - 2 500 314 # Unit is running at 314 MW, Coal flow 226 TPH, Cond. vacuum 0.12, Mills ABCDFH TDBFP A&B are in service Generation : 8.87MU.
#Total Trial operation pending points - 692 : Balance - 78

20 Neyveli CFBC - 1 250 180 # Unit is running at 180 MW Generation:4.97 MU.

21 Neyveli CFBC - 2 250 93 # Unit is running at 93 MW Generation:3.58 MU.

22 Vallur - 1 500 404 # Unit is running at 404 MW. Generation : 9.93 MU.

23 Vallur - 2 500 446 # Unit is running at 446 MW. Generation : 10.23 MU.

24 Vallur - 3 500 0 # Unit is under S/D since 04.06.2017 due to fire accident in TG.

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