Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Performance Analysis 2008

Tripping Analysis

FORCED OUTAGE CY WISE BREAK UP (No. / %)

Heads Pld outage Cal Year 2006 6 / 5.75 Cal Year 2007 7 / 6.10 Cal Year 2008 6 / 6.09

Grid Rest . + Dist

Blr Aux Turb Aux Elect Aux BTL C&I

1 / 0.002
2 / 0.04 4 / 0.23 7 / 0.34 15 / 0.70 1 / 0.01

0 / 0.000
6 / 0.14 6 / 0.09 7 / 0.05 27 / 1.25 15 / 0.08

0 / 0.000
3 / 0.04 2 / 0.23 23 / 0.25 33 / 1.51 8 / 0.02

Others
Fd outage Total Outage

2 / 0.01
32 / 1.33 38 / 7.07

3 / 0.01
64 / 1.63 71 / 7.73

9 / 0.21
78 / 2.26 84 / 8.35

Apr 2008

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # III : Leakage from LHS Eco coil no.32 header joint Root Cause: Weld failure. ACTION PLAN Proper marking and record of defective joints after radiograph

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # III : Leakage from LHS SCW T-1&2 above re-heater regulating stage Root Cause: Attachment weld failure, sample sent to R&D. ACTION PLAN

Exhaustive DPT and checking of attachment welds.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VII : Leakage from water wall (LHS ) tube no -12 towards rear from scaffold door at an elevation of 8.5 mt Root Cause: Ash led air erosion due to gap between LHS & SPanel WW. ACTION PLAN Sealing of gaps between S panel and vertical wall

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VII : both ID & FD fans tripped on Post purge fan trip protection and unit tripped on both FD fans OFF. Root Cause: Defective input cards EB02 in CRB01 panel ACTION PLAN

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VIII : water wall (LHS) tube no -4 towards rear from WWSB No.-84 at an elevation of 18.5 meter Root Cause: shop joint weld defect ACTION PLAN Radiography of shop/erection joints in phased manner during overhaul.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VIII : Unit was desynchronised to attend HRH ERV (no. 23) passing, manual isolating valve was also passing. ACTION PLAN

New ERV was replaced with new one. Servicing of manual isolating valve every overhaul.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VIII : Leakage from water wall Spanel area front side tube no1 from LHS at an elevation of 8.5 mt near scaffold door Root Cause: Attachment weld failure. ACTION PLAN

Exhaustive DPT and checking of attachment welds.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # X : Leakage from from water wall (front side ) tube no -1 towards right from WWSB No.-45. EL-46 mt Root Cause: Shop weld failure ACTION PLAN Radiography of shop/erection joints in phased manner during overhaul.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # X : Unit tripped on GT WTI operated due to the actuation of GT Cooling fan supply change over fault relay Root Cause: Over current relay operation of 415 V in both incomers of ACDB due to the circulating current flown while paralleling of both transformers(11/0.4 KV) ACTION PLAN Review of overcurrent relay setting and time delay.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # X : Leakage from ECO lower bank bottom, vertical joint of inner most tube of coil no 1 from LHS at an elevation of 48 mt. Root Cause: Erection weld failure. ACTION PLAN Radiography of shop/erection joints in phased manner during overhaul.

May 2008

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # III : Tube leakage in Re-heater Regulating stage Coil no. 80 RHS bottom centre bend Root Cause: Flue Gas erosion .
ACTION PLAN

Inspection and thickness survey of bends at all four sides and middle top and bottom. Lifting of 24 coils every year to inspect middle bends of all 288 coils.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VI : Tube leakage in Re-heater Regulating stage Coil no. 31 LHS bottom extreme bend. Root Cause: Flue Gas erosion . ACTION PLAN Inspection and thickness survey of bends at all four sides and middle top and bottom. Lifting of 24 coils every year to inspect middle bends of all 288 coils.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # IX : . Turbine tripped on Cold gas temperature high protection. Both TDBFPs tripped. MDBFP came on auto but it tripped on protection. Boiler tripped on Drum level very low protection Root Cause: Air locking in the TG ECW system ACTION PLAN Presence of NRV between ECW make up tank and suction header. shall be reviewed; matter will be referred to OSEngg.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # X : Unit tripped on Loss of All Fuel protection. Root Cause: Tripping of PA fan-10B on local EPB operation ACTION PLAN EPBs of all PA, FD, ID fans were checked for integrity of fixtures.

Jun2008

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # II Tripped on Loss of Excitation Root Cause: Reason could not be established
ACTION PLAN

Thorough checking of both the DVR and control/Power circuit of Excitation system indicates no abnormality in the system.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # V : Tube leakage in Re-heater Regulating stage Coil no. 144 LHS bottom extreme bend. Root Cause: Flue Gas erosion . ACTION PLAN Inspection and thickness survey of bends at all four sides and middle top and bottom. Lifting of ~50 coils to inspect all 288 coils.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # IV : . Tube leakage ACTION PLAN

in Water Wall S-panel Rear panel tube T161 Root Cause: Impact of falling clinker.

Air distribution plates on RHS (Cor-1,5,4 &8) were inspected and damaged plates were rectified.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VII : Unit tripped on Rotor E/F stage 2 protection. Root Cause: Rotor E/F protection Circuit problem ACTION PLAN Rotor E/F stage 2 protection both auxiliary relay shall be connected to RA7A panel DC circuit alone. Proposal has been sent to OS-CC for concurrence and approval.

Jul 2008

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN

U # V Tripped on Flame failure Root Cause: C&I Control card failure.

The defective NPM12 Card was replaced with another new NPM12 card.

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN

U # II Tripped on Loss of Excitation Root Cause: Defective cards in DVR UM.

The defectives Cards were replaced and the excitation system changed over from Stand-by to main .

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN

U # V Tripped on Cond. Vacuum fail protection Root Cause: Water particles in the vacuum switches

All the vacuum switches were cleaned, recalibrated , fixed back and put into service after wrapping all the switches with suitable polythene covers.

Tripping Analysis
CAUSE OF TRIPPING U # V Tripped on Cond. Vacuum fail protection Root Cause: Micro switches developed problems due to presence of water particles
ACTION PLAN

The vacuum switches were replaced with brand new Ashcroft make vacuum switches. All associated cables and protection block were checked for the second time and found normal. 2 out of 3 logic was also checked and found normal. In future, any switch, with presence water particles, shall be dried and cleaned. If required, the same shall be replaced

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN

U # X Tripped on Loss of all fuel Root Cause: Sudden rupture of strainer change over valve flange gasket of HFO supply line in HFO control station at Boiler firing floor causing oil splashing over leading to fire break out.

It shall be always ensured to replace the gaskets in HFO system with better quality gaskets. Proper control of HFO pressure shall be ensured while taking oil guns into service.

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN

U # IX stopped due to high TG Vibration Root Cause:

Clearances of LP front gland box was higher probably because of higher clearances of horizontal keys of LPT front gland box

The gland box of LP front was centered. Horizontal keys were corrected after built-up and machining. TG Brg 3 was inspected as a preventive measure.

Tripping Analysis
CAUSE OF TRIPPING Station Black-out Root Cause: a). Arcing in VJ#4 R phase breaker ; b) Bus bar differential protection for bus section-I,did not operate even though the relay settings were as per design. ACTION PLAN Measures to prevent arcing in 400KV breakers. Matter has been taken up with M/S CGL (OEM) to study the reason for initiation of arc and suggest remedies for preventing the same. Reviewing of current settings for start relay and differential relay which activate the bus bar protection. Communication in this regard has been sent to GM(PEElect.) and M/s ABB

Tripping Analysis
CAUSE OF TRIPPING U#9 : Water wall Tube leakage Root Cause: Attachment weld failure. ACTION PLAN

Aug 2008

Tripping Analysis
CAUSE OF TRIPPING U#4 : Economiser Tube leakage Root Cause: Maintenance weld Defect. ACTION PLAN Proper marking and record of defective joints after radiograph being done. Welder wise defect rate being maintained for control.

Sep 2008

Tripping Analysis
CAUSE OF TRIPPING U#1 : Unit tripped on Furnace Pr. Low as all running RCF came to minimum loading. Root Cause: Momentary disturbance in Node-2 24 V supply. ACTION PLAN Supply block for Node-2 has been replaced. Controllers supply for RC Feeder will be segregated in 03 different panel (02 RCF from each panel.) in next overhaul by C&I department.

Tripping Analysis
CAUSE OF TRIPPING U#1 : Unit tripped on GT winding Temp high. Root Cause: Power cable joint of main supply to GTMB failed and caught fire, due to which GT protection control cables got damaged. ACTION PLAN During Unit O/H inspection of cable tray in GT yard area will be done, joints will be identified and new cables will be laid. b) Control cable and power cables will be routed through different trays wherever such discrepancy is found.

Tripping Analysis
CAUSE OF TRIPPING U#1 : Stub joint leakage of Regulating stage Reheater coil # 1. Root Cause: The cause of failure is uneven load on hangers. ACTION PLAN Regular DPT is done in all stubs and if required stubs are replaced.

Tripping Analysis
CAUSE OF TRIPPING U#4 : Water wall Tube leakage Root Cause: Attachment weld failure. ACTION PLAN Exhaustive DPT and checking of attachment welds.

Tripping Analysis
CAUSE OF TRIPPING U#8 : Unit tripped on Low Forward power protection Root Cause: Wiring problem and termination problem in the load transducers. ACTION PLAN During recommissioning joint calibration by EMD & C&I will be done to ensure healthiness of load transducers.

Oct 2008

Tripping Analysis
CAUSE OF TRIPPING U#7 : Unit tripped on Furnace Pr. High. Root Cause: Sudden dislodging of accumulated ash into BA hopper . ACTION PLAN When ever slagging tendency is observed : a) proper and timely deashing will be ensured by increasing the frequency. b) Frequency of wall blowers operation shall be increased.

Tripping Analysis
CAUSE OF TRIPPING U#2 : Unit tripped on a) Excitation field failure protection b) Stator earth fault Root Cause: Voltage fluctuations caused due to defective Bus PT of R and Y phases. ACTION PLAN The bus line PTs shall be checked individually and shall be included in the testing check list. New bus line PTs procurement action shall be initiated.

Tripping Analysis
CAUSE OF TRIPPING U#2 : Unit tripped due to Gen bkr. Trip while taking UAT in service. Root Cause: Exact cause of trippig can be established after on line supply change over, if the problem persists. ACTION PLAN a) Control wiring checking shall be done to find out cause of Gen Internal fault protection operation during opportunity. b) UAT change over scheme to be checked during opportunity. c) In SOE, the status of unit and station breaker contacts shall be incorporated.

Tripping Analysis
CAUSE OF TRIPPING U#2 : Unit was manually tripped as light reflection on GT R-phase bus duct was suspected as hot spot. ACTION PLAN At night, hot spots are to be confirmed by making the surroundings dark.

Tripping Analysis
CAUSE OF TRIPPING U#5 : Radiant S/H Tube leakage Root Cause: Short term overheating due to blockage. ACTION PLAN End caps to be provided while cutting the vertical tubes.

Nov 2008

Tripping Analysis
ACTION PLAN U#2 : Unit tripped on The ageing Russian make 415 All ID Fan trip V LT breakers (reserve) needs protection due to to be replaced, Proposal shall tripping of LOPs. be initiated by 31/12/2008. for Root Cause: replacement of reserve The CA bus incomer breakers and equipments got tripped sectionalizing breakers in due to intermittent phased manner. voltage drop as Rphase contact of 415V Availability of supply to standby lub oil pumps/ CA bus reserve equipments from other source incomer breaker was damaged. shall always be ensured.
CAUSE OF TRIPPING

Tripping Analysis
CAUSE OF TRIPPING ACTION PLAN U#3 : Unit stopped due Inspection and thickness to RH Reg stg T/L from survey of bends at all four RHS center bends of sides and middle top and Coil # 134, 135, 137 & bottom. LHS center bends of b) Lifting of ~50 coils Coil # 137 every year & balance based Root Cause: on inspection and thickness survey. The suspected cause of failure is Flue Gas erosion.

Tripping Analysis
CAUSE OF TRIPPING U#4 : Unit tripped twice on Turbine trip protection. Root Cause: The Overheating of TTS supply supervision relay due to partial release of one of the Turbine trip manual push buttons in the control desk ACTION PLAN The Turbine trip manual push button was checked and released properly. The operation of push buttons checked and cleared. Turbine trip to Generator trip timer was replaced.

Tripping Analysis
CAUSE OF TRIPPING U#8 : Unit was manually tripped as drain line (MAL-12) before HPCV2 got sheared just above the erection weld joint. ACTION PLAN Sample being sent to R&D for analysis.

Tripping Analysis
CAUSE OF TRIPPING U#8 : Water Wall Tube leakage on (RHS) near WWSB No.-75 Right Tube no. 1 at an elevation of -18.5 mt. Root Cause: The suspected cause of leakage is Shop Joint failure. ACTION PLAN Shop joint to be inspected and radiographed in phased manner.

Tripping Analysis
CAUSE OF TRIPPING U#10 : Water Wall Tube leakage on (LHS) tube no -1 towards right from WWSB No.-18 at an elevation of 50mt. Root Cause: The cause of leakage is attachment weld failure. ( Membrane welded with the failed tube was having weld defect.) ACTION PLAN Refractory holding plate weld will be checked thoroughly in the wall blowers area and repair work will be taken up as per condition.

Dec 2008

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VIII (08/12/08): TL in Platen S/H panel # 13 and 14 Root cause : Bulging due to suspected long term overheating. ACTION PLAN Regular S/H & R/H Metal Temp monitoring being done and reviewed in DPM. Metal temp to be maintained within prescribed limit by keeping burner tilt down and by giving adequate HP spray.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # IX (09/12/08): TL in W/W S panel. Root cause : Ash laden Air Erosion form the narrow gap between sealing strip and Left Water Wall (This gaps have been sealed during last OH, however, one trapezoidal piece found dislocated.) ACTION PLAN Sealing of gaps between S panel and vertical water wall to be ensured during every OH. In U#10 the above gaps to be sealed during overhaul.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VI (10/12/08): Unit got tripped on Loss of excitation ACTION PLAN Reason for failure of pulse final stage power supply module is to be ascertained to avoid recurrence of such failures. Matter has been taken up with OES M/S BHEL

Root cause : Failure

of DVR-UM Pulse Final stage Power supply module-1

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VII (12/12/08): TL in water wall front side tube no 11 from RHS at 46.5mt. Root cause : Long Term Overheating due to Partial chocking at Ring Header Orifice (30% of the orifice area was blocked with corrosion material)
ACTION PLAN

During OH ring header orifice to be removed and water wall flushing to be ensured as per practice.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # V (13/12/08): TL in SCW near M/H # 14 Root cause : Erection joint failure.
ACTION PLAN

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # IV (17/12/08): Unit got tripped on Generator field brkr. Main exc. trip Root cause : Higher voltage drop when standby exciter was taken into service. Also voltage could not be built up in time
ACTION PLAN

Revision of LMI regarding Change over of exciter in view of the R&M of units with DDCMIS. The LMI for Exciter changeover will be reviewed and revised as per the Unit load conditions b) Reason for failure of power supply card is to be ascertained to avoid recurrence of such failures, Matter has been taken up with OES M/S BHEL

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # X (18/12/08): TL in Spacer tube in between Re-heater panel # 1 & 2 Root cause : Spacer tube in between Reheater panel # 1 & 2 pin-hole fracture in erection joint.
ACTION PLAN

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING U # VIII (28/12/08): Unit stopped due to gasket leakage from drum manhole (RHS).
ACTION PLAN

Manhole cover blue matching to be ensured during OH.

Action Plan to reduce Forced Outages

CAUSE OF TRIPPING Following checks are to be U # VII (30/12/08): TL done during /after every in water wall front side wall blowing : near Soot blower no 5 Rotary motion of wall at 43mt blower to be ensured, Root cause : Due soot Poppet valve closing to blower erosion be ensured after blowing, thickness got reduced If a Wall blower gets in T4 towards right stuck-up inside the furnace, steam to be near WWSB no 5. That isolated immediately and created fish mouth maintenance personnel to opening in the failed be informed. tube.
ACTION PLAN