U#U COH_16_FINAL_10.03.2016

CHANDRAPUR SUPER THERMAL POWER STATION

CHANDRAPUR

ISO 9001- 2000, ISO 14001 and OHSAS 18001 UNIT

A PROJECT REPORT

CAPITAL OVERHAUL JAN - 2016UNIT # 5

(PERIOD: 27.12.2015 TO 30.01.2016)

SUBMITTED BY

Er. P.V.GOSAVI Executive Engineer

Er. S.S.BHANSE Assistant Engineer

Er. P.D.HAJARE Assistant Engineer

Er. S.S.DHERE Assistant Engineer

Er. N.S.KSHIRSAGAR Assistant Engineer

1


QUALITY POLICY:

Chandrapur Super Thermal Power Station of Maharashtra State Power Generation CO. Limited

recognizes its prime role in state power grid and is committed to produce economical and reliable

power in an environmentally sustainable manner with continual improvement in effectiveness of quality

management system.

We shall endeavor to upgrade knowledge and skill of our staff and strive for safe working practices

and minimum occupational health hazards.

QUALITY OBJECTIVES:

Increase in station generation.

Increase in plant load factor.

Reduction in auxiliary power consumption.

Reduction in loss of generation due to O&M problem.

Reduction in forced outages factor.

Increase in station availability.

Reduction in total Nos. of tripping.

Reduction in numbers of tripping due to boiler tube leakage.

Reduction in loss of man days due to accidents excluding fatal accidents.

Imparting training for engineers and workers.

ENVIRONMENTAL POLICY:

Chandrapur Super Thermal Power Station of Maharashtra State Power Generation Co.Limited is

committed to produce power to the use modern technology and work practices for prevention of

pollution.

2

We are committed to:

Carry out with environment legislation and regulation.

Carry out with C. R. E, P. and corporate policy.

Reduction in consumption of natural resources by optimum utilization of coal, oil and water.

Conservation of water by recycling water for ash disposal.

Minimization of pollution by promoting fly ash utilization.

Prevention of pollution by increasing green belt area.

Reduction of SPM level of stack emission.

Continual improvement in effectiveness of environment management system.

The environment al policy will be reviewed for objectives and targets at appropriate time.

OCCUPATIONAL HEALTH AND SAFETY POLICY:

Chandrapur Super Thermal Power Station of Maharashtra State Power Generation Co. Limited is

committed for continual improvement in health and safety performance of all our employees.

We are committed to continually improve the OHSMS by:

Identifying and assessing all types of OHS risk and take proactive step to reduce the significant risks,

in turn reduce occurrences of accidents.

Identifying, updating and Carried outlying with all applicable statutory requirements.

Creating awareness about occupational health and safety amongst all employees, contractors and

contract labors and training them adequately for safe work practices.

Preventing injury, loss of property and controlling occupational health problems, following appropriate

measures in respective areas of work.

3


UNIT-V CAPITAL OVERHAUL

PREFACE

CSTPS is a quality conscious, thermal power station. It is the First Power Station in the history of

MSPGCL and first amongst all the State Electricity Board's in INDIA to get prestigious ISO-9002

certification, then ISO-9001 certification And ISO-14000 for its Environmental Management System

and OHSAS 18000.

In order to continuously upgrade and maintain the quality, Capital overhaul of unit-V was declared

W.E.F. 27.12.2015. Boiler validity was up to 03.04.2016.

During this overhaul, major thrust was given on:

1. Replacement/Servicing of passing valves of boiler and turbine side.

2. Removal, servicing, calibration & restoration of SADC Power Cylinder.

3. Overhauling of CCW 5C & BFV seal ring replacement.

4. Work of separation of ACW return line from CCW hot water outlet line.

5. Servicing of APH including basket replacement.

6. Servicing of Burner Tilt including coal compartment assemblies replacement.

7. Seal trough cleaning.

8. Maintenance/Servicing of ESP.

9. Work of repairing /replacement of riser valves of cooling tower.

10. Servicing/ Calibration of Boiler and Turbine side control valves.

11. CONDENSER TUBE CLEANING BY SULPHAMIC ACID.

12. Cleaning of Pent house, Repair of pent house, dog house & cat house.

13. A-type of C/M-A, B, C & H mills.

14. Bottom Ash hopper refractory replacement.

15. Arrest air ingress in the boiler.

16. Complete overhauling of BT mechanism .

17. Repairs of overheated / eroded water wall tubes, SH / RH tubes, LTSH tubes, economizer tubes.

18. Turbine all bearing inspection and LP turbine overhaul.

19. Calibration of various instruments.

20. TDBFP-6B over-haul work.

21. HPT Module servicing work.

4

THIS OVERHAUL REPORT OF U # 5 IS DISTRIBUTED IN FOUR PARTS.

Part I : Pre overhaul report, unit history and planned O/H activities.

Part II : Actual overhaul activities.

Part III : Post overhauls activities.

Part IV : Overhaul expenditure.

5

INDEX

PART-I

PRE OVERHAUL REPORT, UNIT HISTORY AND PLANNED O/H ACTIVITIES :

A. Staff arrangement.

B. Unit History.

C. Set withdrawn activities.

D. Problems faced during operation.

E. Major activities planned.

PART-II

ACTUAL OVERHAUL WORKS CARRIED OUT :

A. Boiler maintenance - II

B. Turbine maintenance - II

C. ODP - II

D. Electric Maintenance - II

E. Instrumentation& Control – II

F. Testing – II

PART- III

A. LIGHT UP, ROLLING AND SYNCHRONIZATION OF UNIT.

B. POST OVERHAUL ACHIEVEMENTS.

C. POST OVERHAUL PENDING DEFECTS.

PART- IV

A. OVERHAUL EXPENDITURE.

6

PART - I

PRE OVERHAUL REPORT, UNIT HISTORY AND PLANNED O/H ACTIVITIES:

A. Staff arrangement.

B. Unit History.

C. Set withdrawn activities.

D. Problems faced during operation.

E. Major activities planned.

UNIT-5 OPERATION STAFF ARRANGEMENT:

PROJECT MANAGEMENT:

Er. P. V. GOSAVI Executive Engineer Project Manager

Er. S.S. BHANSE Assistant Engineer

Er. N.S. KSHIRSAGAR Assistant Engineer

Er. S. S. DHERE Assistant Engineer

Er. P.D. HAJARE Assistant Engineer

ISOLATION & NORMALIZATION:

Er. A.M. KATHOYE Executive Engineer Team Manager

Er. M.H. ALI Assistant Engineer

Er. S.R.GITE Assistant Engineer

Er. G.B. NIMKAR Junior Engineer

Er. V.K.CHAUDHARI Junior Engineer

7

TURBINE SIDE ACTIVITIES:

Er. G.S.KULSANGE Executive Engineer Team Manager

Er. A.D.MOHOKAR Dy Executive Engineer

Er. H.S. GHUGE Assistant Engineer

Er. Y.W.ASAWALE Junior Engineer

BOILER SIDE ACTIVITIES:

Er. A.V.YELE Executive Engineer Team Manager

Er. P.W. RAMTEKE Addl. Executive Engineer

Er. N.S.KADAM Addl. Executive Engineer

Er. S.B. KAMBLE Dy. Executive Engineer

Er. V.B.RAMTEKE Assistant Engineer

ODP ACTIVITIES:

Er. P.N. WARUDKAR Executive Engineer Team Manager

Er. K.Y. UIKE Dy. Executive Engineer

Er. R.R. KALE Assistant Engineer

Er. P.P.ROY CHAUDHARY Assistant Engineer

SHIFT STAFF ARRANGEMENT:

1) Shift In Charge In overhaulPeriod:

Er. J.D. BAWANE Addl. Executive Engineer

Er. R.S. NAIDU Addl. Executive Engineer

Er. V.M. JOSHI Dy. Executive Engineer

Er. D.D. KAMBLE Dy. Executive Engineer

Er. M.T. BULKUNDE Dy. Executive Engineer

8

2) Control Desk Engineer in Shift:

Er. P.P. PATIL Dy. Executive Engineer

Er. S.K. TETWAR Assistant Engineer

Er. S.V. MESHRAM Assistant Engineer

Er. G.S. CHIKANKAR Assistant Engineer

Er. S.S. THOMBARE Assistant Engineer

3) Deputation to other section:

A) TURBINE MAINTENANCE:Er. B.S. PETKAR Junior Engineer

B) BOILER MAINTENANCE-II:

Er. D.M. CHANDAVALE Assistant Engineer

C) INSTRUMENT&CONTROL-II:

Er. J.A. DHANGAR Assistant Engineer

9

UNIT HISTORY:

M.S.E.B. (Now Maharashtra State Power Generation Co. Limited) has constructed a Coal Based

Thermal Power Station at Chandrapur, in Maharashtra State. This is on the Broad Gauge rail route of

the Central Railway, on Delhi-Chennai trunk route. A site is situated near village Neri and Durgapur on

Chandrapur Tadoba road at a distance of 6-7 km. from Chandrapur. Broad gauge railway siding and

all weather approach road connect the project site.

Chandrapur Super Thermal Power Station of generating capacity of 2340 MW has adequate water

apart from the huge coal reserve in Chanda - Wardha Valley.

STAGE UNIT SANCTION COMMISSIONING COMMERCIAL OPERATED

I1 JUL-1976 15/08/1983 01/11/1985

2 JUL-1976 11/07/1984 16/09/1985

II3 FEB-1979 03/05/1984 01/04/1986

4 FEB-1979 08/03/1986 04/11/1986

III5 JUN-1981 22/03/1991 01/12/1992

6 JUN-1981 11/03/1992 01/12/1993

7 FEB-1991 01/10/1997 01/03/1998

CLIMATIC CONDITION

The climatic condition of Chandrapur is as follows-

a)Elevation : 192.3 meters above MSL

b)Maximum temperature : 50 0C

c)Minimum temperature : 6 0C

d)DBT / WBT

Summer : 112.5 0F dbt/81.5 0F wbt

Winter : 88.2 0F dbt/78.2 0F wbt

e)Annual rainfall : 750 millimeters

10

UNIT DETAILS :

(1) Boiler Registration No : MR 11729

(2) Boiler

Type- Controlled Circulation with Rifled Tubing CC+, Radiant Reheat, Dry Bottom, Top

Supported.

Design pressure : 204 kg/cm2

SH outlet : 179 kg/cm2 / 540 0C

(3) Furnace

Type- Balanced Draft Furnace with Fusion Welded Water Walls

Width : 18034 mm.

Depth : 15289 mm.

Volume : 14580 m3

Fuel Heat Input : 1225.5 X 106 kcal / hrs.

(4) Turbine

o Three cylinders reheat condensing Turbine.

o Single - flow HP turbine with 18 reaction stages. Type: H30 - 63 - 2

o Double - flow IP turbine with 14 reaction stages per flow. Type: M30 - 50

o Double - flow LP turbine with 6 reaction stages per flow. Type: N30 - 2x10 – 2

RATING:

Normal rating 500 MW

TMCR 524.4MW

11

SPEED:

Rated speed : 3000 rpm.

Standard over speed trip setting : 3330 rpm max.

Generator & Exciter:

Generator Type THDF 115 / 59

Main Exciter Type ELR 70 / 90 -30 / 6 -20E5

Pilot Exciter Type ELP 50 / 42 - 30 / 16 E7

Rated Data & OutputsTurbo-Generator

Main Exciter Pilot Exciter

Apparent Power 588 MVA 65 kVA

Active power 500MW 3840 kW

Current 16.2kA 6300A 195 A

Voltage 21±1.05 kV 600 V 220 ± 22 V

Speed 50 s -1 50 s -1 50 s -1

Frequency 50 Hz 400 Hz

Power factor 0.85

Inter conn. of Stator winding YY

H2 Pressure 3.5 Bar

Cont. Perm. Unbalanced Load 8 %

GENERATOR VOLUME AND FILLING:

Generator volume (Gas volume): 80 M3

CO2 Filling Quantity: 160 M3 (STP),

H2 Filling Quantity: 480 M3 (STP)

12

HISTORY OF THE UNIT # 5:

ParticularsUNIT - 5

(500 MW)

Boiler No. MR-11729

Comms. date 22-03-91

Coal firing 31-03-92

Commr. op 01-12-92

SR.NO. TRIPPED SYNCHRONISED REASONS / REMARKS DATE & TIME DATE & TIME

1 06/07/94 20.15 13/09/94 04.05 CAPITAL OVERHAUL

2 05/10/96 22.30 22/10/96 13.47 ANNUAL OVERHAUL

3 01/12/97 22.10 16/12/97 07.40 ANNUAL OVERHAUL


5 11/08/00 22.30 19/08/00 16.15MINI

OVERHAUL

6 18/07/01 00.00 14/08/01 18.40 ANNUAL OVERHAUL


8 01/07/05 00.00 15/12/06 22.54

ANNUAL OVERHAUL

( Extended due to

turbine breakdown)

9 14/08/08 19.30 19/09/08 05.50

ANNUAL OVERHAUL /

LPT & IPT inspn and

Reheater Girdling Loop

& LTSH coil repl'nt.

10 16/04/2010

11 29/12/11 12.13 08/01/12 19.54 MINI OVERHAUL

1214/07/2013

00:00/02/2014 ANNUAL OVERHAUL

13

14

Year wise Generation, PLF, AVF:

Year GEN PLF AVF

(Mus) (%) (%)

1991-92 1.224 16.88

1992-93 1035.820 23.65 44.43

1993-94 1877.224 42.86 78.71

1994-95 2130.928 48.65 73.85

1995-96 3194.136 72.73 90.81

1996-97 3383.520 77.25 89.63

1997-98 3279.445 74.87 89.74

1998-99 3115.664 71.13 88.27

99-2000 3049.040 69.42 80.76

2000-01 3428.528 78.28 90.26

2001-02 3376.464 77.09 87.14

2002-03 3493.448 79.76 93.11

2003-04 3335.120 75.94 83.62

2004-05 3734.357 85.26 90.78

2005-06 989.873 22.60 24.20

2006-07 1121.927 25.61 27.45

2007-08 3384.122 77.05 89.81

2008-09 2958.086 67.54 85.44

2009-10 3158.904 72.12 94.31

2010-11 2325.151 53.09 72.46

2011-12 3144.648 71.60 92.26

2012-13 3208.469 73.25 96.19

2013-14 1170.367 26.72 36.17

15

2014-15 3039.905 69.40 91.07

ANALYSIS OF GENERATION & LOSSES

16

Loss Of Generation Report For Unit-V For The Period: 23/08/2012 To 27/12/2015

17

SR NO

P A R T I C U L A R S

2013-14

(Aug-13 to Mar-14)

2014-152015-16

(Till Jan-16)Total

Mus. % Mus. % Mus. % Mus. %

1 Possible generation 2544.000 100.00 4380.000 100.00 3300.000 100.0010224.00

0100

2 Actual generation 361.369 14.20 3039.905 69.40 2178.224 66.01 5579.498 54.57

3 Loss of generation 2182.631 85.80 1340.093 30.60 1121.776 33.99 4644.500 45.43

A] Unit overhauls 0.000 0.00 0.000 0.00 50.583 1.53 50.583 0.49

B] External factors 72.699 2.86 707.706 16.16 477.202 14.46 1257.607 12.30

i) Low system demand 20.764 0.82 147.846 3.38 239.454 7.26 408.064 3.99

ii) Poor coal receipt 0.000 0.00 232.341 5.30 0.000 0.00 232.341 2.27

iii) Poor coal quality 51.935 2.04 276.127 6.30 201.250 6.10 529.312 5.18

iv) Wet coal problems 0.000 0.00 16.084 0.37 36.368 1.10 52.452 0.51

v) System problem 0.000 0.00 35.308 0.81 0.130 0.00 35.438 0.35

vi) Water Shortage

problems0.000 0.00 0.000 0.00 0.000 0.00 0.000 0.00

vii) Excessive Rains 0.000 0.00 0.000 0.00 0.000 0.00 0.000 0.00

C] Op. & Mt factors 2109.932 82.94 632.387 14.44 593.991 18.00 3336.310 32.63

1) Boiler tube leakage 26.840 1.06 167.141 3.82 236.101 7.15 430.082 4.21

2) Pr.parts/pipes/valves 0.000 0.00 78.798 1.80 0.000 0.00 78.798 0.77

3) Coal mills 0.115 0.00 2.120 0.05 2.753 0.08 4.988 0.05

4) ID/FD/PA fan 0.000 0.00 10.936 0.25 1.392 0.04 12.328 0.12

5) Flame fail/Furnace

pr0.000 0.00 0.000 0.00 1.308 0.04 1.308 0.01

18

SR NO


2013-14

(Aug-13 to Mar-14)

2014-152015-16

(Till Jan-16)Total



0100



A] Unit overhauls 0.000 0.00 0.000 0.00 50.583 1.53 50.583 0.49






v) System problem 0.000 0.00 35.308 0.81 0.130 0.00 35.438 0.35

vi) Water Shortage

problems0.000 0.00 0.000 0.00 0.000 0.00 0.000 0.00


C] Op. & Mt factors 2109.932 82.94 632.387 14.44 593.991 18.00 3336.310 32.63



3) Coal mills 0.115 0.00 2.120 0.05 2.753 0.08 4.988 0.05

4) ID/FD/PA fan 0.000 0.00 10.936 0.25 1.392 0.04 12.328 0.12


pr0.000 0.00 0.000 0.00 1.308 0.04 1.308 0.01

TRIPPING REPORT FOR UNIT-V THE PERIOD: 20/02/2014 TO 09/06/2015 :

UNIT-5 TRIPPING OH TO OH

SR.TRIPPED DATE

& TIMESYNCHRONISED

DATE & TIMEREASONS / REMARKS

1 20/02/14 20.51 21/02/14 03.56Unit tripped on Gen. H2 cold gas temp.

After cooler very high. (Other Problem)

2 28/02/14 18.37 03/03/14 13.39

Unit withdrawn to attend Boiler Tube

Leakage

(Zone - Steam Cooled Wall). The

synchronization delayed due to Barring

gear jamming problem. (Turbine

misc/others - 6.825 Mus)

3 05/05/14 00.40 08/05/14 06.20

Unit tripped on "Condenser pressure

very very high" due to tripping of all

CEP's. CEP-5C R-Phase lug detached

and cable touched to body, due to

sulfation effect. CEP-5B R-phase earth.

CEP-5A R/C valve stuck up due to

positioner failure. Turbine barring stalled

on 05-05-2014 @ 08:20 hrs. (Electrical

Problem - 11.667 Mus, Turbine

Brg./CV/rotor/bal - 27.166 Mus from

00:00 hrs of 06-05-2014.)

4 17/05/14 23.20 18/05/14 11.00

Unit Withdrawn to attend hot spot at

GTR Y phase. The work is carried out

by MSETCL 400 KV R/S. (System

Problem)

5 21/05/14 12.46 25/05/14 14.37Unit withdrawn due to Boiler tube

Leakage (Zone : Economizer)

19

SR NO


2013-14

(Aug-13 to Mar-14)

2014-152015-16

(Till Jan-16)Total



0100



A] Unit overhauls 0.000 0.00 0.000 0.00 50.583 1.53 50.583 0.49






v) System problem 0.000 0.00 35.308 0.81 0.130 0.00 35.438 0.35

vi) Water Shortage

problems0.000 0.00 0.000 0.00 0.000 0.00 0.000 0.00


C] Op. & Mt factors 2109.932 82.94 632.387 14.44 593.991 18.00 3336.310 32.63



3) Coal mills 0.115 0.00 2.120 0.05 2.753 0.08 4.988 0.05

4) ID/FD/PA fan 0.000 0.00 10.936 0.25 1.392 0.04 12.328 0.12


pr0.000 0.00 0.000 0.00 1.308 0.04 1.308 0.01

6 12/06/14 10.05 12/06/14 12.38Unit tripped due to generator rotor E/F

relay 64F tripped.(Electrical Problem)

7 12/06/14 19.14 16/06/14 12.25

Unit withdrawn due to Boiler tube

Leakage

(Zone : Super heater)

8 23/06/14 22.00 24/06/14 06.05Unit withdrawn due to abnormal sound

in Primary Air-Heater-B.

9 01/08/14 11.48 04/08/14 16.12Unit withdrawn due to Boiler Tube

Leakage at Steam Cooled Wall.

10 04/08/14 23.19 05/08/14 04.23Unit Withdrawn due to condenser

vacuum very low.

11 05/08/14 05.17 05/08/14 18.02Unit Withdrawn due to Primary Water

Temp. very High.

12 06/09/14 18.3008/09/14 00.10

Unit withdrawn to attend HPH FD-41

Valve problem

13 09/09/14 05.15 14/09/14 12.51

Unit withdrawn to attend HPH FD-41

Valve problem & due to critical coal

stock

14 14/09/14 21.02 15/09/14 10.58 Unit Withdrawn due to PA Fan problem

15 19/09/14 19.13 20/09/14 01.25Unit withdrawn due to PAH-5B rotor

stopped

16 05/12/14 14.58 05/12/14 22.28Unit withdrawn for GTR B Phase jumper

work by MSETCL. (System problem)

20

17 18/12/14 11.01 18/12/14 14.02Unit tripped on "Loss of fuel indication"

(T&IC problem)

18 22/02/15 11.36 25/02/15 18.44Unit withdrawn due to condenser tube

leakage.

19 26/02/15 21.39 03/03/15 14.27Unit withdrawn due to BTL. (Zone -

Super heater)

20 26/03/15 16.44 27/03/15 14.03Unit Tripped due to Starting Device

Card Failure


Economizer)

22 29/04/15 08.07 30/04/15 09.39

Unit withdrawn to jamming of SAH-5A

due to dislocation of one no of grating, 1

basket fall down on GD & 1 basket

entrapped in rotor & sector plate . (Air-

Preheater)

23 01/05/15 04.30 10/05/15 17.25Unit withdrawn due to SAH-5B roter

jam.(Air heater Problem)

24 04/06/15 01.01 04/06/15 05.45Unit tripped due to malfunctioning of

FSSS card (T&IC Problem)

25 04/06/15 06.05 04/06/15 08.43

Unit tripped on cold gas temp high due

to closing of H2 temp control valve.

(Others Problem)


Economizer )


Economizer )

21

28 25/09/15 21.40 28/09/15 22.02Unit Withdrawn due to BTL (Zone - WW

&Economizer)

29 30/09/15 17.36 05/10/15 05.07 Unit Withdrawn due to BTL (Zone - RH)

30 15/10/15 18.00 19/10/15 23.55Unit Withdrawn due to BTL (Zone -

Water Wall)

31 03/11/15 03.28 03/11/15 09.45

Unit tripped as EHG got zero due to

malfunctioning of EHG control final

output card. (T&IC Problem)

32 17/11/15 21.13 18/11/15 05.34

Unit tripped on Condenser Pressure

very High as all running CCW Pumps

tripped due to DC control supply failure

(Electrical Problem)

33 18/11/15 06.35 18/11/15 09.23

Unit tripped as EHG got zero due to

malfunctioning of EHG control final

output card. (T&IC Problem)

34 17/12/15 17.18 17/12/15 19.55 Unit tripped on Flame Failure

35 21/12/15 23.47 22/12/15 05.15Unit tripped on Condenser vacuum very

low

22

C. SET WITHDRAWAL ACTIVITIES:

a) OPERATIONAL ACTIVITIES:

TG Set withdrawn on 27/12/2015 at 18:55Hrs.forcapital overhaul work.

Before withdrawing TA set was sharing 371.01 MW load.

And following were the unit parameters at 13.58hrs.on 26/12/2015.

GENERATOR TRANSFORMER PARAMETERS AS ON 26/12/2015 AT 19:15.00HRS

Sr No PARAMETER GTR-R GTR-Y GTR-B

1 OIL TEMP (Deg. C) 43 47 47

2 WDG TEMP (Deg. C) 48 52 52

3 OIL PUMP RUNNING 1 & 3 1 & 3 1 & 3

4 OIL LEVEL 50 % 40 % 40 %

5 SILICA COLOR BLUE BLUE BLUE

6 TAP POSITION 3 3 3

23

BOILER TURBINE GENERATOR

TUR THR PR

126.01 Kg/cm2.HPT TOP / BOT TEMP.

515 / 518 0C

Gen. Voltage

21.00 KV

MS TEMP

525.770C

IPT TOP / BOT TEMP

326 / 3410C

Gen phase current

R- 10.1, Y- 10.3, B-10.3 K Amp

HRH PR. –

31.51Kg/cm2.

HRH Temp-

5280C

HPT FIRST STG PR.

125 Kg/cm2.

Exciter field current

1942 AMP

MAX. TG BRG VIBR.

23.71 MIC (BRG NO. 07)

GEN FREQ. 50.10 Hz MVA

7.13MVAR

MAX. SHAFT VIBR.

61 MIC.( No. 01)GEN FREQ. 50.10 Hz

Condenser Vacuum

-8630 MMWCLMAX GEN. SLOT TEMP 72.510C

MAX CORE TEMP 51.100C

NEG. PHASE SEQ CURRENT 0.5 %

ESP PARAMETERS ON DT: 18/12/2015:

PASS A – FIELD VOLTAGES IN KV & CURRENT IN mA :

FIELD 1A1 1A2 2A1 2A2 3A1 3A2 4A1 4A2 5A1 5A2 6A1 6A2

VOLT 30 U/V U/V 36 40 53 42 U/V 42 44 39 42

mA 237 U/V U/V 221 352 00 278 U/V 590 41 426 65

PASS B – FIELD VOLTAGES IN KV & CURRENT IN mA :

FIELD 1B1 1B2 2B1 2B2 3B1 3B2 4B1 4B2 5B1 5B2 6B1 6B2

VOLT 30 35 36 28 55 33 42 44 37 41 28 32

mA 32 65 172 82 08 16 04 90 00 123 24 467

PASS C – FIELD VOLTAGES IN KV & CURRENT IN mA :

FIELD 1C1 1C2 2C1 2C2 3C1 3C2 4C1 4C2 5C1 5C2 6C1 6C2

VOLT 16 16 22 45 U/V 32 34 42 U/V U/V 54 51

mA 00 00 00 82 U/V 24 442 574 U/V U/V 24 73

PASS D - FIELD VOLTAGES IN KV & CURRENT IN mA :

FIELD 1D1 1D2 2D1 2D2 3D1 3D2 4D1 4D2 5D1 5D2 6D1 6D2

VOL

T36 34 U/V 26 04 37 39 34 35 36 39 35

mA 98 205 U/V 32 728 303 328 295 295 426 221 418

24

TURBINE BEARING AND SHAFT VIBRATIONS IN MICRONS ON DT: 18/12/2015,AT: 23.09 HRS.

Time

HRS

ABSOLUTE BEARING SHAFT

1

HPT F

2

HPT R

3

IPT R

4

LPT R

5

GEN F

6

GEN R

7

EXC R

1

HPT F

2

HPT R

3

IPTR

4

IPT R

7

EXC

23.09 4.83 3.46 6.70 5.8 25.09 3.89 16.1 70.91 36.31 50.72 58.5 24.4

FOLLOWING ACTIVITIES WERE CARRIED OUT AFTER TRIPPING OF TA SET : BOILER SIDE ACTIVITIES :

1. Boiler draining started on 28/12/2015 at 14:20Hrs.at drum metal temp top/bottom-78/740C.

2. Furnace pressurasation test was carried out on dated 29/12/2015 from 10:45 Hrs. to 12:30 Hrs. at

1424 T/Hr air flow and +52 mmwcl furnace draftwith 2 I.D.fan and 2 F.D. fan in service and leakages

observed were marked with paint.

3. CAVT was carried out in second pass of boiler with 3 I.D.fan and 2 F.D. fan in service on dtd.

29/12/2015 from 14:00 to 18:00 Hrs. at air flow 1436 T/Hr. and -5.9 mmwcl furnace draft.

TURBINE SIDE ACTIVITIES : A. ACW, CCW system :

1. CCW sump make up stopped on dated 30/12/2015 at 14:30Hrs.& level was 190.300 MSL.

2. CCW sump level low alarm not appeared even if sump level drop down to 191.300MSL (Alarm setting

25

191.300 MSL). And CCW pump has to stop manually as no pump was tripped even if sump level

drops down to 190.300 MSL.

3. ACW-5C withdrawn at 10:00 AM on 30.12.2015.ACW-B TRIPPED at 23:30 on 31.12.2015. Sump level

very low (189.600 MSL).

4. MOT coolers, seal oil coolers, IA Compressor & SA Compressor, F/F water supply was provided for

cooling purpose during above period.

B. HYDROGEN PURGING :

1. On dated 27/12/2015 at 18:58 Hrs. unit withdrawn for Capital overhaul work.

2. H2 purging started (at pr.3.1 kg/cm2) at 10:07hrs.on29/12/2015 by opening H2 purging valve from

turbine basement.

3. CO2 filling started at (0.2kg/cm2)13:20Hrs. on Dated 29/12/2015

4. CO2 purity 100.0% achieved on dtd 30.12.2015. Total CO2 cylinders consumed 65Nos.

5. Dry instrument air filling started at 00:50hrs, Dated 31/12/2015 and stopped at 08:15hrs. On

31/12/2015and CO2 purity obtained 0% and air pressure boost-up to 3 kg/cm2 at 08:15hrs.

6. Generator leak test and depressurization of air started dated 01/01/2016 from 09:15hrsand air

pressure kept 0.5 kg/cm2, on dated 01/01/16 at 12.20 hrs.

7. Turbine Barring stopped at 02:45 hrs. On 01/01/2016.HPT top/bottom casing temperatures were

109/110oC.

HPT COOLING CURVE :

HPT CASING COOLING CURVE

Set withdrawn on Dt. 27/12/2015 AT 18:50Hrs.Barring stop on dt.01/01/2016, AT 02:45Hrs.Average

rate of cooling 3.20C per hour.

26

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 540

50

100

150

200

250

300

350

400

450

500

HPT TOPHPT BOTTOM

HPT Casing top / bottom cooling temp ( 0 C ) :

Sr.No. Hrs. TOP Bottom Sr. No Hrs. Top Bottom

1 0 463 448 19 36 293 260

2 2 451 434 20 38 284 252

27

3 4 438 420 21 40 277 244

4 6 426 404 22 42 270 237

5 8 417 385 23 44 262 230

6 10 409 374 24 46 255 223

7 12 400 363 25 48 248 217

8 14 391 352 26 50 241 211

9 16 383 347 27 52 234 204

10 18 375 338 28 54 227 198

11 20 367 329

12 22 358 320

13 24 349 311

14 26 341 302

15 28 332 293

16 30 321 288

17 32 314 276

18 34 307 268

PROBLEMS FACED DURING OPERATION:

TURBINE SIDE :

1) SAC-5A, DIS NRV PASSING

2) SAC-5B, SAFETY VLV LEVER NOT AVALABLE

28

3) SAC-5C, BELTS LOOSE

4) IAC-5A OIL LEAKAGE FROM FIY WHEEL SHAFT

5) IAC-5B,SOUND FROM NRV

6) AIR WASHER -1A, SAFETY GUARD N.A.

7) ALL COMPR ACW VLV REQ LUBRICATION

8) AIR DRYER BLOWER NO-2,HAVING VIBRATION & ABNORMAL SOUND

9) BOILER FILLING PUMP U5 & U6 HAVING GLAND LEAKAGE

10) COMPR SV -3 AIR LEKAGE FROM PLUNGER

11) AIR DRYER 4WAY VLV REQ SERVICING

12) MDBFP-5C,R/C VLV BONET LEAKAGE

13) MDBFP-5C,BOOSTER PUMP MECH SEAL STEAM ,WATER LEAKAGE

14) MDBFP-5C,BOOSTER PUMP END DROP BY DROP OIL LEAKAGE

15) MDBFP-5C R/H & S/H SPRAY NRV PASSING

16) CEP-5B, HAVING STUFFING BOX LEAKAGE

17) MAIN CRH LINE,IMPULSE LINEABOVE MAL STATION HAVING LEAKAGE

18) EX-32,VLV SEAL WATER LEAKAGE FROM ACTUATOR

19) CEP-5A,5B,5C SUCTION LINE DRAIN TO BE MODIFIED

20) VACCUME PUMP -5A SEPERATOR TANK VENTGUARD N.A.

21) GTR –B PH ,ACW I/L STRAINER HOLE OBSERVED

22) MOT COOLER NO-2,HAVING DROPWISE LEAKAGE FROM FLANGE

23) MS ATMOSHERIC DRAINS VLV 3NOS PASSING

24) ALL MAL STATION ISOL VLV & MOTORISED VLV NEED SERVICING

25) CD-31 & 34 VLV DROPWISE LEAKAGE FROM BONET

26) MDBFP-5D ,WORKING COOLER CHOCK UP

27) PRIMARY WATER PUMP STN RASIN TANK I/L VLV PASSING ,NOT ISOLATES WHILE RASIN

CHANGEING

28) G.D. PUMP NO-1,DIS VLV LEAKAGE

29) G.D.PUMP NO-1.DIS LINE LEAKGE NEAR FLANGE

30) MOT COOLER I/L & O/L ACW LINE VENT VLV NEED REPLACEMENT

31) MD BFP-5C,SH SPRAY LINE DRAIN VLV PASSING

32) MDBFP-5C,HAVING LEAKAGE FROM MAIN PUMP BODY FLANGE

33) MDBFP-5D,MECH SEAL COOLER CHOCKUP

34) EX- 10 VLV IN OPERATIVE35) EX – 6 VLV IN OPERATIVE36) TDBFP-5B,MAIN PUMP HAVING HIGH VIBRATIONS AS PER CMC REPORT

29

37) PROVISION OF FIRE FIGHTING WATER FOR U5 COMPR OPERATION

ODP-II SIDE DEFECT: 1) CCW PUMP SUMP MAKEUP VLV (OLD) NOT WORKING2) CCWPH PNEUMATIC MAKEUP VLV JAM3) ACW PUMP R/C, DIS VLV HAMMERNG SOUND4) CCW-5B PUMP, DIS BFV NOT OPENING ON AUTO MODE5) COOLING TOWER -5A & 5B RISER VLV JAM6) CCW-5C PUMP GLAND FOLLOWER DAMAGE.

EM-II SIDE DEFECTS :

1) 5CWXA & 5CTXA TRANSFORMER OIL GAGE FAULTY (LVL NOT SEEN)

2) 5CWXA TRANSFORMER TAP CHANGER TANK OIL LVL NOT SEEN

3) COOLING TOWER TRANSFORMER AREA POOR LIGHTING

4) COMPR BKR PANEL (ALL) LOCK KEY JAM

5) BUS DUCT DRYER TOWER HEATER NOT WORKING

6) ALL GTR,UAT,STN TRANSFORMER GAGE GLASS NEEDS CLEANING

I&C-II SIDE DEFECTS :

1) BRG DE SIDE TEMP GAGE FAULTY

2) CCW-5A, 5B COLD AIR TEMP GAGE N.A.

3) ALL IAC & SAC DIS PRESS GAGE REQ CALIBRATION

4) SERVICE AIR CCW-5B,MOTOR RECIVER TANK PRESS GAGE FAULTY

5) CONDENSER I/L & O/L TEMP & PRESS GAGES REQ REPLACEMENT

6) BUS DUCT DRYER TEMP & PRESS GAGES NEED CALIBRATION

7) GD PUMP DIS LINE PNEUMATIC VLV NOT OPERATING ON AUTO

8) H2 PRESS GAGE AT LOCAL REQ CALIBRATION

9) HOT WELL TEMP GAGE RHS NEED CALIBRATION

10) EX-10 VLV , NOT WORKING ON AUTO

11) MAIN TG EHG HAVING HUNTING

ET-II SIDE DEFECTS

1) IAC-A SAC-A, ANNOUNSATION N.A.

2) GT-5, CW FLOW LOW ALARM FAULTY YET PERSIST ON CUP-19

3) GT COOLER TROUBLE FAULTY ALARM ON CUP-19

30

4) BUS DUCT DRYER HEATER NOT WORKING

CM SIDE DEFECTS :

1) 5CTXA AND 6CWXC TRANSFORMER SLAB LEAKAGE ABOVE DUCT

2) ACW & CCW PUMP HOUSE TERES LEAKAGE

3) TERES DRAIN PIPE NEAR H2 ROOM ,HEAVY LEAKAGE ON LIGHING PANEL

F/F SIDE DEFECTS :

1) F/F VLV ABOVE HOTWELL MAKEUP STATION HEAVY LEAKAGE.

BOILER SIDE : 1. A-4 PIPE FROM FURNANCE HEAVY LEAKAGE AND FLAME COMING OUTSIDE.( SPARK)

2. WIND BOX DUCT LEAKAGES AT RHS/LHS. ALL CORNOR EXP.JOINTBOILER INSULATIONS

DAMAGED AT CORNERS, ESPECIALLY AT 23 MTRS UNIT #6 SIDE AND AT OVERFIRED

DAMPERS (ALL CORNERS), CONTINEOUS ASH COMING OUT OF FURNACE AND GETTING

ACCUMULATED AT CORNERS.

3. ESP HOPPER D31– FOREIGN MATERIAL.

4. DRUM VENT LINE PUNCTURE

5. DRUM VENT B-56, B-72 JAM / INOPERATIVE.

6. SH DRAIN STATION DRAIN V/V GLAND LEAKAGES – 3 NOS.

7. SOOT BLOWER FALNGE JOINT GASKET HEAVY LEAKAGES 29,31,64.

8. SOOT BLOWER FALNGE JOINT GASKET LEAKAGES 23,51,54,55,61,69,85,88,103

9. ESP FIELD 4D2. 2A1, 1D2, 4B1, 1A1, 1A2 – NEED INTERNAL INSPECTION

10. CRM 1A SHAFT SHIFTED/JAM

11. CBD V/V AT 23 MTRS GLAND LEAKAGE

12. PAH 5A & 5B –HOT AIR LEAKAGE FROM MANHOLES & EXPANSION JOINTS

13. OIL GUN AB3 STEAM ISOLATING V/V BONET LEAKAGE

14. ISO V/V TO SH SPRAY V/V SS12 BODY LEAKAGE

15. FO STATION ATOM STEAM TRACING LINE V/V GLAND LEAKAGE

16. BCW PUMP NO.1 COOLING LINE V/V GLAND LEAKAGE

17. ISO V/V TO RH SPRAY V/V R11 BODY LEAKAGE

18. ALL CLINKER GRINDERS NEED INTERNAL INSPECTION

19. SEAL TROUGH HAVING LEAKAGE ABOVE C/G 1B, 2A & 2B

31

20. C/A TANK NO. 1 & 2 WALKING GRILL BROKEN

21. C/A FLUE GAS HOPPER NO 3 & 4 - RAILING & GRILL BROKEN

22. C/A TANK NO. 1 - TEALEPIECE CHOKEUP.

23. BV C/A TANK NO. 1 - TEALEPIECE CHOKEUP.

24. ALL COLD AIR DAMPERS TO BE PROVIDED WITH CHAIN & HANDLE & MAKE THEM FREE

25. ALL B/ASH MANUAL HYJECTOR V/V NEED TO MADE FREE

26. C/M 5E LOP OIL SEAL LEAKAGE. C/M 5A & 5B HAVE MINOR LOP LEAKAGE.

27. C/M 5B J2 ASSY SHAFT SEAL LEAKAGE

28. BOILER FILLING STATION ALL V/V NEED SERVICING

29. SLURRY TRENCH STRAINER NEEDS TO BE REPLACED

30. ID FAN A,B,C,D ACW LINE VALVE INOPERATIVE

31. ID FAN A DUCT LEAKAGE AT LOWER SIDE NEAR INSPECTION DOOR

32. ID FAN D DUCT LEAKAGE AT UPPER SIDE NEAR INSPECTION DOOR

33. ID FAN A LOP II OIL LEAKAGE THROUGH INSPECTION GLASS

34. ID FAN C OIL LEAKAGE THROUGH OIL LEVEL GAUGE

35. ALL ID FAN INSPECTION DOOR ROPE NEEDS TO BE REPLACED

36. SUMP SELECTION VALVE FOR BOTTOM ASH, FLY ASH NOT FREE

37. BOTTOM ASH, FLY ASH SUMP SELECTION VALVE A,B,C SERIES NEEDS SERVICING

38. ASH WATER MAKE UP VALVE PASSING

39. ESP HOPPER C-11,C-21 HOPPER ASH LEAKAGE ANS INPEC. DOOR CHECKING REQ.

40. SIDE HEAVY LEAKAGE AND HEATER BELOW LINE STEAM AND OIL LEAKAGE

41. LDO/HFO TANK SCALE PATTY PROPER FITTING . SCREW FITTING REQ.

42. TANK HEATING MAIN AND TANK HEATING INDIV. V/V PASSING REPL. AND CHECKING REQ.

43. FD FAN-A/B, PA FAN-A/B ACW LINE PRESSURE AND TEMP. GUAGE ISO. V/V NOT

OPEN/CLOSE/JAM ALL PUMP ACW INLET AND OUTLET V/V SERVICING REQ.

44. SUPER HEATER ALL DRAIN V/V JAM SERVICING REQ. AND MAKE FREE

45. PAH-5A/5B,SAH-5A/5B ACW LINE TEMP.AND PRESSURE ISO. JAM AND REPL. REQ. AND AIR

HEATER ALL ACW INLET AND OUTLET AND DRAIN V/V JAM NOT OPEN/CLOSE REPL. REQ

46. GD-6A1/6A2,6B1/6B2,6C1/6C2,6D1/6D2 AND 7A/7B/7C/7D SERVICING REQ.

47. NEW FITTING DUCT HOPPER NOT INOPERATIVE I&C=II U=5 HEAD TOLD NO INFORMATION

AND NOT DONE PROTOCAL

48. SUPER HEATER SPRAY DRAINS V/V ARE PASSING AND NOT OPEN/CLOSE JAM AND REPL.

REQ.

49. C/M-5A TO 5H HOT AIR GATE SEAL PASSING AND DUCT LEAKAGE, C/M 5B - HOT AIR DUCT

RUPTURED.

32

50. ALL ID FAN ACW LINE DRAINS V/V AND INLET AND OUTLET V/VS ARE JAM AND THREAD

DAMAGED SERVICING AND REPL. REQ.

51. GH ELEVATION GH-2/3 OIL GUN NO PROPER SPACE TO BE FIT OIL GUN AND RAILLING

CUT REQ.

52. ALL DRUM VENT AND STARTUP VENT SERVICING REQ.

53. F.O HEATING U=5 MAIN V/V AND INTER CONNECTION V/V AT OHP JAM MAKE FREE

54. PAH-5A/5B SAH-5A/5B AIR HEATER FLUSHING LINE ALL V/VS ARE JAM NOT OPEN/CLOSE

AND SAH-5A FLUSHING LINE HEAVY LEAKAGE NEAR AIR HEATER

55. GAS DAMPER GD-4B2 UNDER PERMIT ABOVE ONE YEAR GD-4A1,4A2,4B1 FULL NOT OPEN

CLOSE FROM LOCAL AND LEVER NOT ENGAGE SERVING REQ.

56. BSWBOOSTER PUMP-5A NRV PASSING AND SERVING REQ.

57. PRI GAS INLET DAMPER GD1A - INOPERATIVE FROM DESK

58. C/M 5D & 5F HAVE ONLY ONE LUB OIL COOLER

59. BOTTOM RING HEADER INSULATION ESP SIDE - SHEETS HANGING

60. HFO PUMP 5C - STEAM LEAKAGE NEAR SUCTION V/V

61. IMPULSE LINE OF ECONOMISER FEED LINE HEAVY LEAKAGE

62. ID FAN A,B,C,D - DROP BY DROP OIL LEAKAGE FROM PRESSURE GAUGES

63. BCW PUMP 5A/5B/5C ITS ACW COOLER INLET AND OUTLET V/V JAM SERVICING REQ.

64. PAH-5A/5B SAH-5A/5B ITS PRESSURE GUAGE AND TEMP. GUAGES LOP CALIBRATION

REQ.

65. ACW FD-5A/5B PA FAN-5A/5B PRESSURE AND TEMP. GUAGES FAULTY AND CALIBRATION

REQ.

66. C/M-5A TO 5H MOTOR TEMP. GUAGES ARE FAULTY AND CALIBRATION REQ.

67. ESP PASS -A/B/C/D FIELD AND CRM/ERM PANEL BOX DISPLACED AND GROUND

POSITIONCALIBRATION AND REPL. REQ.

LIST OF THE MAJOR WORKS PLANNED DURING ANNUAL OVERHAUL:

BOILER MAINTENANCE SECTION :

1) BOILER PRESSURE PARTS:

33

a) Repairs of Water Wall :

1. Tubes with more than 25% erosion will be replaced.

2. Tubes with more than 25% erosion will be replaced.

3. Sacrificial S.S. shields are put in coal/Air Carried out and also at 9 M level.

4. Welding of trapezoidal wear bar between two tubes of side wall near neck tubes.

5. Repair of Z panel hangers in cat house

6. Attending air ingress through Z panel scallop bar

7. Replacement of damaged insulation in SB and pent house area

8. Metallurgical analysis of WW tubes for deposit analysis.

b) Wall RH :

1. Eroded RH Bends and liners will be replaced.

2. Alignment of wall RH tubes near div. Panel will be done.

c) Repairs of Div.Panels : 1. Replacement of eroded S.C. spacer tube.

2. Fitting of flexible connectors.

3. Replacement of distorted girdling loops and fitting of flexible connectors.

d) Repairs of PSH :1. Radiography of site welding joints in ckt no 1 of thick 9.5 mm

2. Replacement of eroded and distorted tubes.

3. Refitting of damaged flexible connectors

4. Replacement of SC spacer

5. Welding of SS pads.

e) Repairs of RH (rear) :1. Position of mechanical binders in rear RH will be changed to avoid further fretting

2. Visual Inspection of RH outlet header stubs for overheating

3. Alignment of coils no 41 to 46 without cutting the tubes

34

f) Repairs of RH (Front) : 1. Inspection steam cooled spacer tube and its connectors for fretting

g) Repairs of screen tube :

1. Replacement of eroded tubes and bends at bottom and top.

h) Repairs of LTSH :

1. Lifting of assay no 1,3,56 and 58 for inspection in upper LTSH.

2. Eroded tubes and bends at inlet and terminal will be replaced as per thickness report.

i) Repairs of ECO (upper) :1. Lifting of assy no 1,3,63,65 for inspection

2. Lifting of coils with misaligned tubes

3. Eroded tubes and bends will be replaced.

4. Inspection of eroded 90 deg. bends near header of coil no 1, 2, 3, 128, 129, 130

j) Repairs of ECO (middle and lower) :

1. Lifting of coils with misaligned tubes

2. Eroded tubes and bends will be replaced.

3. Repairs of cassette baffles

h) Repairs of steam cooled wall :

1. Inspection of bends of manholes and LRSB openings and replacement of eroded bends

35

2) Other : a) Inspection of drum :1. Inspection and cleaning of drum internally.

2. Checking of phosphate dozing line, feed line for any damage.

b) Inspection of bottom ring header : 1. Inspection of orifices from bottom ring header, after blowing air and after hydraulic test for any

blockage.

c) Repairs in pent house :

1. DP and MPI testing of all stub welding of Pl. S.H. inlet header will be carried out.

2. Sealing ropes of peep holes and manholes will be replaced.

3. Replacement of gaskets of peep holes and manholes

4. Leakages through skin welding of roof will be attended by replacing warped skin plate.

5. Cleaning of Sky climber rope opening in pent house.

d) BCW P umps : 1. Cleaning of coolers- 3 nos

e) Servicing of safety valve :

1. Servicing of Drum, SH, RH, PRDS, SB safety valves

2. In-site seat cutting if required

3. Pressure testing of safety valves

f) Servicing of HP valves :

1. Servicing of SH spray Isol. Valves- 8 no’s

2. Servicing of RH spray Isol. Valves- 8 no’s

36

3. Servicing of SH drain valves at 26 m- 16 no’s

4. Servicing of drum vents, SH vents, RH vents, Boiler drain valves at 0 m

5. Servicing of PRDS inlet isol. Valve, NRV and ASP16

6. Replacement of gland packing of 2" valves- 50 no’s

7. Replacement of gland packing of 1" valves- 50 no’s

g) Servicing of burner tilt : 1. Servicing of burner tilt

2. Synchronization of all coal and air tips will be ensured.

3. Freeness of burner tilt operation for ± 30 degree will be ensured.

h) Servicing of APH :1. Inspection of guide bearing in position.

2. Inspection of support bearings in position

3. Replacement of all radial and bypass seals.

4. Replacement of axial seals

5. Cleaning of all baskets by hydro jetting

6. Replacement of rotor angle, T-bar, support grills

i) Servicing of dampers / gates : 1. Repair of APH inlet and outlet gas dampers

2. Servicing of APH inlet and outlet air dampers

3. Servicing of actuators-16 no’s

j) Servicing of ID,PA,FD Fans

1. Inspection of bearings.

2. Checking bearing clearances.

37

3. Servicing of IGV.

4. Replacement of PA Fan-A both bearings along with housing.

5. Servicing of PA/FD discharge dampers/gate

3) ESP:

a) Repairs of Bottom Ash Hopper :

1 Inspection& repairs of damaged refractory.

2. Inspection & repairs of SS wire mesh.

3. Inspection & repairs of SS seal plates.

4. Inspection & repairs of refractory cooling water system.

5. Inspection & repairs of hopper flushing nozzles.

6. Repairs of bottom ash hopper by welding.

b) Servicing of ash feed gates, bottom ash hyjectors& HP / LP Water Valves.

1. Inspection & repairs of ash feed gate.

2. Overhaul of bottom ash hyjectors.

3. Overhaul of SG roll clinker grinder.

4. Servicing of HP & LP water valves.

5. Replacement of damaged HP & LP water pipe lines.

c) Servicing / Repairing of Corse Ash Evacuation System

1. Servicing of feeder ejectors.

2. Gland 6 mm:

3. Valve plates:

4. Consumable set:

5. Jet pump spares

6. MSERW Pipes 200, 100, 80 NB

d) Servicing / Repairing of Fly ash Evacuation System :

1. Servicing of feeder ejectors assembly.

2. Servicing of feeder ejectors

38

3. Gland 6 mm

4. Valve plates

5. Consumable set:

6. Replacement of damaged HP water Pipe lines.

e) Repairs of Flue Gas duct from Eco outlet to ESP inlet area (LHS & RHS). Removal of ash & debris from duct & stack hopper :

1. MS plates 3.15 to 12 mm thick

2. Bracing pipes of various Dia.

f) Overhauling / Repairs of complete Electrostatic Precipitator :1. CRM shafts

2. CRM Hammers

3. ERM shafts (V/H): Sets each.

4. ERM hammers

5. Set ring

6. Shock bar guide angle

7. Shock bar assembly

8. Inner arms

9. Plain brgs

10. Bush bearings

11. Thrust bearing

12. Cup Washers

13. Sleeve Tube 50mm.

14. Sleeve Tube 40 mm.

15. GD Screens.

g) CFD of flue gas & hot gas duct & rectication thereoff : i) Diversion plates, chemical bonded refractory.

h) Replacement of Metallic Expansion Joints of flue gas duct : 1. Eco O/L, PAH Horizantal duct, ESP I/L duct

39

i) Replacement of Fabric Expansion Joints of flue gas duct : 1. APH vertical duct, PAH Horizantal duct, APH O/L horizantal duct

j) Replacement of Worn out coal pipes and bends :

1. Proper scaffolding for replacement of pipes and bends.

2. Replacement of coupling rubber gaskets

k) Servicing & replacement of classifier vanes :1. Proper scaffolding

2. Inspection of vanes

3. Replacement of vanes

4. Servicing of vanes

l) Servicing of coal mill drive air system :

1. Removal of bowl hub skirt.

2. Check the gap between inner ring and outer ring and fitment as per requirement.

3. MDV flap

m) Servicing / Repairing HAG/CAD/ actuators /CF gates / seal air fan filters-

1. Servicing / repairing of hot air gates and dampers.

2. Servicing / repairing of cold air gates and dampers.

3. Servicing / repairing of CF inlet and bunker outlet gates.

4. Cleaning of seal air fan filters.

4) CAPITAL OH of coal mill & coal feeder of 5A/5B/5C/5F

TURBINE MAINTENANCE SECTION

40

1) HP TURBINE OVERHAUL:

1. Removal of Spray Insulation & Piping

2. Dismantling of HP module .

3. Re-Assembly

4. Steam Flow Path Clearance Checking

5. Assembly Checks and Correction

2) IP TURBINE OVERHAUL:

1. Removal of Spray Insulation & Piping

2. Dismantling of IP Module & Dismantling checks

3. Alumina Blast Cleaning of Rotor and casing

4. IP Gland seal clearance checking & setting.

5. Steam Flow Path checking

6. Inspection of Blades and Fact Finding

7. Assembly checks and correction

8. Assembly of IP module & Restoring of piping.

9. Checking & Correction of Pipe Pull in HRH pipes.

3) LP TURBINE OVERHAUL :1. Dismantling of LP & Dismantling Checks

2. Removal of rotor, inspection & Alumina Blasting

3. DPT & MPI of Free Standing Blades of LP

4. NFT of Free Standing Blades of LP

5.Casing Alumina Blasting

6. Inner-Inner casing Ovality & Steam Flow Path Check

7. Placement of Rotor in Position, checking of clearance

8. Box up of LPT turbine

9. LP Gland Box Clearance adjustment of Labyrinth

10. Hot well inspection

4. GENERATOR & EXCITER :

41

1. Generator Rotor Thread out .

2. Leakages test of Hydrogen System

3. Inspection of Seal Bearing

5. TURBINE VALVES : 1. HP Stop & Control Valve

2. IP Stop & Control Valve

3. LP Bypass Stop & Control Valves

4. CRH & Exraction FCNRV's

6. HP BYPASS VALVE SERVICING : 1. Valves Servicing and Internal inspection

7. GOVERNING SYSTEM : 1. Setting of Governing System Charecterstics

2. All Accumalators N2 Pressure Checking & Filling

8. BEARING (7 NOS ) : 1. Dimensional checks of journal /bearings/keys etc

2. Bearing UT & DPT, Bearing Bedding Inspection

3. Oil Catcher Fins Renewal

4. Replacemnt of Jacking Oil Hoses

5. Bottom Saddle & Torus piece checking & correction

6. Bearing no. 5 ,6 & 7 -IR cheaking of bearing insulation

7. Check Labyrinth Rings and replace seal strips

9. LUB OIL SYSTEM : 1. Bucket strainer cleaning & Lub Oil filter cleaning

2. JOP ilter Cleaning / Replacement.

10. MOT COOLER : 1. Cooler Cleaning.

42

11. MAIN OIL PUMP (MOP) : 1. Inspection and Overahuling of MOP.

2. Checking of various parts of MOP for clearance.

3. Checking of Bearing and matching

12. COOLERS : 1. H2 cooler Cleaning & Hydraulic testing.

2. Exiter Coolers Cleaning & Hydraulic testing.

13. HPT/IPT & VALVES : 1. Spray insulation of HPT/IPT & Valves

14. HRH / MS STRAINER : 1. Inspection & Bonnet Seal Replacement

15. COOLERS CLEANING & HYDRAULIC TEST : 1. MDBFP Coolers ( 8 Nos. )

2. TDBFP Coolers ( 4 Nos. )

3. Vaccum Pump Coolers ( 2 Nos. )

4. Primary Water Coolers( 3 nos. )

5. Seal oil Coolers ( H2+ Air Side ) 4 Nos

6. GTR Coolers ( 6 Nos. )

7. FRF Coolers( 2 Nos. )

16. CONDENSER TUBE CLEANING : 1. Cleaning By Bullet Shot

2. Gravity Test

17. HP VALVES / NRV INSPECTION & SERVICING :

43

1. MS & HRH strainer drain valves (MS-502, 504, 506 & 508 HR - 113, 502, 504, 506 & 508 , MAL

11,12,13,14, 22,26,28,34,54,65,66) ,MS 104.

2. HP Heater Extraction Valves ( EX : 1A & 2A) & EX-1,2,3,4,5,

3. BD ( Iso.), BPE-1 & 2, HPB 101 & 102 FD : 56 & 58.

4. AS-2, 3, 4, 9, 10, 11 & 12.

5. TDBFP Valve EX27,28,29,30, 31 & 32.

6. Passing Valves as per defect list.

18. ACW LINE VALVES SERVICING : 1. H2 Cooler I/L & O/L ( 8 + 1 nos. )

2. Exciter cooler I/L & O/L ( 4 nos. )

3. Vacuum Pump Coolers I/L & O/L ( 4 Nos. )

4. MOT coolers I/L & O/L ( 4 nos. )

5. TDBFP A & B coolers ( 16 nos. )

6. MDBFP C & D coolers main I/L & O/L (4nos. )

7. Seal Oil Coolers ( H2 + Air ) 8 nos.

8. SAC / IAC ( 21 nos )

9. LPBP Water Injection ( 5 nos. )

10. FRF coolers ( 4 + 1 nos. )

11. PW Coolers ( 6 + 1 nos. )

12. GTR R-Y-B I/L ( 9 nos. )

19. FEED STORAGE TANK ,DEAERATOR INSPECTION: 1. Inspection and cleaning of FST & Deaerator

2. Checking of Deaerator Nozzle and replacement

20.HP & LP HEATERS : 1. Internal inspection, Conducting Tube leakage test

21. CEP -5A : 1. Pump Overhaul

22. CEP RC VALVES :

44

1. Recirculation Valve Internal Inspection

23. ALL BFP'S VALVE SERVICING : 1. Suction Valve

2. Superheater Spray Valve

3. R/H Spray Valve

4. TDBFP-5A & 5B RC valve replacement

5. TDBFP-5BMain

6. Pump Cartridge Replacement

24.VACUUM PUMP 5A : 1. Pump Overhaul

25.TDBFP A & B : 1. Tank Cleaning

2. All AOP & JOP Filter Cleaning

OUT DOOR PLANT MAINTENANCEA. VALVE REPLACEMENT/SERVICING:1. A, B Series suction KGV servicing /Replacement work

2. Fly ash Sump Selection Valve replacement/servicing.

3. Bottom ash Sump Selection Valve servicing/replacement.

4. RAW water inlet valve 500 NB servicing/replacement.

5. RAW water inlet valve 350NB servicing

6. ETP v/v servicing

7. Series drain Valve replacement/ servicing work

8. Seal water line, cooling water line valves replacement/ servicing work

a) HPAWP/LPAWP Inlet & outlet valve servicing work

b) HPSWP/LPSWP Inlet& outlet valve servicing work

45

B.CLEANING WORK : 1. Ash water Tank cleaning work

2. Seal water Tank cleaning work

3. Drain sump Cleaning Work

4. Ash Surry sump cleaning work

C.FLUSHING NOZZLE REPLACEMENT :

1. Bottom Ash sump, Fly Ash Sump, A, B, C sump, flushing nozzle And its line replacement work

D. STRAINER AND NRV SERVICING :1. HPAWP/LPAWP NRV & strainer servicing work.

E. GRATING AND SUPPORT REPLACEMENT : 1. A, B, C sump damaged grating replacement work

2. Bottom ash & Fly ash trench grating Replacement work

3. Various Pipe support replacement/ strengthening work

F. PIPES REPLACEMENT: 1. 5A line- sump suction bends checking, suction pipe replacement, ASDP-3 expander to bend & bend to

reducer replacement, ASDP-4 bend to bend repl.

2. 5B line- sump suction bend checking, sump suction pipe replacement, BSDP-1 HP repl, BSDP-2 HP & VP repl, BSDP-3 expander to bend, bend to reducer repl, BSDP-4 bend to bend repl.

3. 5C line-sump suction bend checking, sump suction pipe replacement, CSDP-1 HP & VP repl, CSDP-2 HP & VP repl, CSDP-3 expander to bend, bend to bend, bend to reducer repl, CSDP-4 expander to bend, bend to bend repl.

4. Seal water pump eroded line replacement work

5. Seal water, cooling Water, air system rusted line replacement work

G.CT FAN O/H :1. CT FAN O/H

2. CT FAN GB O/H

46

H. CT POND :1. Work of cleaning of CT pond area, outlet strainer of CT Pond Repairing.

2. Work of both side nozzle replacement which are missing & nozzle cleaning of tower 5A & 5B

3. Overhauling of CCW 5A

4. ACW Pumps Thrust bearing oil replacement 5A, B, C

5. CCW Pumps Thrust bearing oil replacement 5B, C, D

6. CCW Pumps gland replacement 5B, C, D

7. ACW Pumps gland replacement 5A, B, C

8. CCW Pump Butterfly valve Hydraulic system servicing & power pack oil replacement 5B, C, D

9. ACW/CCW pumps suction strainer repairing & fitting work

10. ACW/CCW SUMP CLEANING WORK and hydro cone checking

I. VALVE SERVICING/REPLACEMANTWORK: 1. Work of ACW recirculation / outlet line's valves, discharge line valves, vent valve checking,

repairing/replacement

2. Work of repairing /replacement of riser valves of cooling tower 5A & 5B

3. Work of checking, repairing/replacement of Blow down valves of CT 5A & 5B

4. CCW pump butterfly v/v seal ring replacement

J. SUPPORT AND APPROACH PROVIDING: 1. Work of CT fan cells approach way railing & gear box protection cage railing repairing work

2. Drift eliminator cleaning

3. CT Fan foundation frame replacement/ reconditioning CT Fan

4. Hot water asbestos cement (broken) pipe replacement

5. Hot water pipe Header painting & riser v/v painting

6. Work of cleaning of Hot water Basin of cooling tower Unit-5 at cstps, Chandrapur.

ELECTRICAL MAINTENANCE1. GENERATOR / GEN. EXCITER : Preventive Maintenance of Generator PT cubicle & NGR.

PMG & Pilot excitor

Diode wheel assemble

Preventive Mainenance of Generator PT cubicle & NCR"

47

2. BATTERY MAINTENANCE: P/M & Capacity Test of +/- 24V G1/G2 Battery sets.

P/M & Capacity Test of Station Battery set for battery set1&2 and UPS Battery set.

3. HT TRANSFORMERS: A. 400KV Connections : 400KV side HV bushing & LA connection tightness of GTR-5R/5Y/5B.

B. Internal inspection of GTR 5Y, UAT-5B & 5D : Complete draining of oil.

Internal inspection through inspection window carried out& attending defect if any found.

Replacement of MOG along with float, gauge glass, PRV.

Replacement of gasket & activated alumina if required.

Oil Filteration work.

Assistance in cooler testing if required.

External cleaning of surface,Applying first coat of red oxideand two coat of epoxy paint, writing

identification/name plate.

Replacement of rubber bellow if required.

C. Oil filteration of GTR-5R, UAT-5A,5C,SAT-3B: Oil folteration arrangement and filteration of oil to be carry out.

Leakage attending or attending defect if any found.

Oil Filteration

Assistance in cooler testing if required.

External cleaning of surface.

Replacement of rubber bellow if required.

D. P/M of X'mers , M. B. & NGRs of GTR-5R/ 5Y/ 5B, UAT-5A /5B/ 5C/5D, Stn-3, SAT 3A/B: Tightness checking of HV / LV connections

Silica gel replacement.

Oil topping up , if required

Oil lekage attending , if any

48

Rubber bellow replacement , if required

NGRs / MBs Preventive maintainance.

E. Painting of GTR-5R,5Y,5B : Cleaning of transformer .

Painting of transforrmer as per scope of work.

F. Preventive Maintenance of Generator & UAT Bus Duct and painting of Generator and UAT bus duct outside A-axis:

Opening and closing of inspection window covers.

Checking & cleaning of insulators, rubber bellows and replacement if required.

Sealing of unwanted openings using sealant.

External & internal cleaning of bus duct.

Cleaning and painting of outer surface with one coat red oxide and two coat of paint

G. Work of replacement of black metal of GTR-5R,5Y,5B;UAT-5A,5B,5C,5D; ST-3;SAT-3A,3B Removing of old black metal

Cleaning of surafce , removing of bush tree

Spreading of new black metal of existing size.

Dumping of removed black metal as per instruction of site incharge.

H. P/M of Dry Type Transformer 5XA, 5XB, OXA1, OXA2 LXA1, LXA2 : Opening of doors of the X'mer

Cleaning of X'mer with air

Tightness checking of HV / LV connections

including tap changer

Rubber bellow replacement, if required

NGRs / MBs Prev. Maint.

IR measurement

49

4. HT MOTORS: A. Overhauling of HT motors ID fan 5A,5D ; PA FAN 5A ; FD FAN 5B : Removal of power cable, earthing connections, control cables etc

Shifting of motor to repair bay.

Dismentalling of motor completely

Replacement of bearings, if required.

Stator & rotor varnishing.

Box up of motor completely

Shifting of motor to the location.

Alignment of motor with the gear box

Normalization of motor & trial.

Coal mill motors 5A, 5B, 5F.

B. P/M of HT Motors :COAL MILL- 5C,5D,5E, 5G, 5H; BCW-5A, 5B, 5C; CEP-5A/5B/5C; MDBFP 5C,5D; ID 5B, 5C:

Cleaning & Connection Tightness checking at motor and switchgear end& rectification, if required.

IR value measurement

Silica gel replacement of power JB .

C. Cooler Cleaning of HT motors, PA-5A, 5B; MDBFP-5C, 5D: Dismantling of I/L & O/L pipelines.

Removal of coolers with Hydra or EOT crane.

Cleaning of coolers with brush, cleaning agent.

Hydraulic testing of cooler.

Restoration of cooler along with pipelines.

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5. LT MOTORS A. Overhauling of critical LT motors SAF-5A,5B; Vaccum pump-5A; AC scanner fan;

control fluid-5A,5B; AC-JOP; Main Turbine AOP-1,2; SOP-1,2; PAH 5A/5B 1,2; SAH5A/5B 1,2; TDBFP AOP 5A/5B 1,2:


Removal of power cable, earthing

connections, control cables etc








B. Coal Feeder motor overhauling works along with DE side pinion hrading and check nut provision:

Removal of power cable, earthing

connections, control cables etc





DE side pinion check nut provision works.





C. Preventive Maintenance of LT Motors of unit # 5 :

51

Cleaning & Connection Tightness checking at motor and switchgear end & rectification , if required.

6. HT/LT SWITCH-GEARS :A. P/M of Unit Board 5A, 5B,5C, 5D,5E: Cleaning of panels & Power Connection Tightness checking and rectification, if required.

Servicing of Breakers.

Replacement of faulty component.

IR measurement.

B. PM of 5PA , 5MA , 5MB, 5MC, 5MD, 5EMPA , 5ME, 5MG, Soot blower Boards: Cleaning of panels & Power Connection Tightness checking and rectification, if required.


Replacement of faulty components.

IR measurement.

C. PM of DCDBbs ODA, ODB Boards Cleaning of panels & Power Connection Tightness checking and rectification, if required.


Replacement of faulty components.

IR measurement.

7. AHP/ESP MAINTENANCE :

A. Maintenance of ESP A Pass, B Pass, C Pass, D Pass: Prev.Maint.of 5EPPA,5EPPB,5EPPC,5EPPD/ ACP panels

Prev.Maint.of ESP A-Pass/B-Pass/C-Pass/D-pass fields,hopper heaters / support & shaft

insulators heaters

Prev.Maint.of all ERM / CRM of A-Pass/B-Pass/C-Pass/D-Pass

Prev. Main. of 5EPXA X'mer/5EPXB X'mer/5EPXC X'mer/5 EPXD X'mer.

B. Retrofitting of 3.3 KV HV Breaker by HT contactor : Retroffiting work as per order.

52

C. Maintenance of AHP : P/M of 5AHS 3.3 KV BOARD

P/M OF 5AHPA 415 VOLTS BOARD.

D. Preventive maintenance of rectiformer: Checking of power connection & rectify if found defective.

Oil leakge arresting by tightening of gasket.

Replacement of HV bushing oil if found leakage .

Through Cleaning of rectiformers.

E. PM of ESP Heater along with replacement if required & preventive maintenance of ERM/CRM motors:

Checking of all ESP heater and replacement if required.

Cleaning of Insulator.

PM of all CRM/ERM motor and replacement if required.

8. COMPRESSOR ROOM :

A. Preventive Maintenance of DG set:

Cleaning of panels & Power Connection Tightness checking and rectification, if required


9. LIGHTING / WELDING SUPPLY: Electrical supply to various Agencies woking for capital O/H of the unit.

INSTRUMENTATION & CONTROLSA. Removal, Servicing and Normalization of 16 Nos. of HEA Igniters with Power Cylinder, Limit

Switches and Igniter Transformer. Removal and restoration of 16Nos. HEA spark rod assemblies after Servicing, Repairing if Reqd,

Testing Healthiness of Spark Tip, HT Cable with Transformer & Limit Switches with remote Trials.

B. Removal, Servicing, cleaning, checking, calibration and Normalization of 28 Nos. of Flame scanners.

53

Removal, Servicing, cleaning, replacement of PCBs, sensing glass etc., checking healthiness of flame sensitivity, calibration and Normalization of 28 Nos. of Flame scanners.

C. Servicing of SADC Power Cylinder. Removal & restoration of 64 nos. SADC power cylinders after servicing of Positioners, Pilot assembly,

painting Stroke Calibration with remote joint trial. 8 nos. of air line filter regulators servicing & restoration ( 2nos. in each corner)

D. Mill O/L Temp. T/C’s checking, Thermo well checking , replacement if found faulty and both point availability/checking.

Removal , Cleaning , Re-mounting, Connection normalization of Mill O/L T/C’s with T/W’S. Cable laying for T/C – 2nd point.

E. Flushing of 100 nos. Impulse Line. Disconnection of instrument impulse pipe , Flushing & re-connection with Teflon tape.

F. Servicing of Bottom Ash / Burner Tilt / PA Fan guide vane power cylinder. De-linking, Removal, Dismantling, Servicing of Power Cylinder, Seal replacement, Assembling ,

Testing for Zero leakage’s with full air pressure.

G. TRB’s / TRT’s / JB’s cleaning, Painting Sealing, connections tightening & Broken TB’s replacement.

Cleaning and Painting of TRB’s / JB’s Broken T.B’s replacement connection tightening after rail cleaning.

H. Removal and Restoration of all corner solenoid/C/M HAG & reject gate solenoid along with tubing & leak isolating valve checking/ replacement.

Removal, cleaning and restoration of all solenoid valves along tubing of all corner-56nos. Removal, cleaning and restoration of all solenoid valves along tubing of C/M HAG-8no. Removal, cleaning and restoration of all solenoid valves along tubing of C/M RG sol-16no All leak/passing instrument isolating valves checking/ replacement.-100nos

I. Servicing of C/M’s HAG/ all corner solenoid, Limit Switches & air line, oil filter cleaning and oil top up.

Removal, cleaning & contact functional checking of L/S(16 no) Filter element removal, cleaning & fresh oil top up.

54

All corner solenoid- 56nos.

J. Servicing/ Calibration of Boiler and Turbine side control valves- 75 nos. Removal, Servicing , Remounting, Calibration of Stroke with PFT. servicing/cleaning and calibration of E/P converters, Air lock relays, Air filter regulators

K. Calibration of Servicing of Positioners, pilot assemblies, an lock relays, E/P converters, Air line regulators.1. C/M’S CAD/HAD – 16nos. Calibration of stroke with PFT& remote trial.1. Burner tilt.2. PA Fan vane

L. Servicing and calibration of ID/FD/PA/BCWP/ CWBP all instruments & protection trial. Removal, Servicing, Calibration. Re-mounting as per B/M ,T/M & E/M Schedule

M. Removal / Calibration & Re-mounting of Removal, Cleaning, Calibration(a) PA Hdr Press. Switches. Re-mounting after impulse line flushing(b) Furnace Press. Switches. Connections normalization & isolating manifold valve position normalization

N. Servicing of C/M’s Seal air valve power cylinders with Solenoids & Limit Switches Removal, Servicing Testing of Power Cylinders Servicing & Testing of Solenoids and Limit Switches

O. Removal & Normali-sation of Boiler side Instruments as per B/M – II , E/M – II requirement . Removal of Connections/ Instruments Normalization after clearance

P. Internal Inspection of O2 Probe & Replacement of guide pipes & V guards. O2 LHS/RHS disconnection removal, inspection. Replacement of Protective tube & V guard strengthening. Calibration

Q. Removal & Restoration of all elevation pressure gauges. Removal of all corners press gauges.

55

Cleaning of all gauges. Calibration of all Gauges.

R. Removal, mounting, laying, dressing & checking of SH/RH metal temp thermo-couples as per BM-II schedule.

Removing of T/C as per BM-II. Checking and Replacement if found faulty. Restoration after BM-II clearance Connection cleaning, tightening, signal checking upto panel.

Attending of all S/D defects /Modifications:-S. Calibration of critical and Non-critical Instruments as per List / Schedules – 200 nos. Confirm validity of MCAL/ SMCAL Removal; of Instrument & Cleaning Calibration & ISO Tagging Remounting & Normalization

T. Removal of ESP / Coarse Ash / FGDH / Economizer A/V & W/V Solenoid after B/M – II clearance

B/M – II Clearance & removal of Solenoids.

U. Removal, Servicing and painting of ESP/Coarse ash power cylinder. Servicing & Testing of Solenoids Removal cleaning, servicing, checking and painting of power cylinder. Re- installation of Solenoids after B/M – II clearance Local Remote Joint Trial. ESP all rows air filter regulators servicing & accumulator oil level top up.

V. Removal / Servicing & Remounting of AHP Ash water make up valves, series sump make valves, ETP valves, RC valves, suction valves solenoids as per ODP – II schedules.

Removal, cleaning / Servicing of Solenoids. Remounting & joint trial

W. AHP A/B/C Series & HP Ash water tank Level controller testing after Sensor Cable & bolt replacement

Removal of Old cables with bolts & replacement by new. Ckt testing & Protection trial

56

Calibration of all series seal Water Press Switches, HP Ash Water Disch. Press. Switches

X. Calibration of Bottom ash/PAH/SAH/FGDH/Economizer/ESP/AHP all instrument. Removal &cleaning of press. gauges. Calibration & tagging. Remounting & connection normalization.

Y. Calibration of Boiler drum press. Gauges. Removal, Cleaning & Calibration.

Z. ID/FD/PA/BCWP protection Trials

AA. Boiler protection Trial.

BB. Replacement/ Retrofitting of MOT and FRF tank Level Amplifiers with Cali-bration. Removal, Cleaning, Calibration of probe with amplifier units & tagging.

CC. Removal, Servicing/ Testing & restoration of HPT/ITP top/bottom & TSE thermocouples with T/W.

Removal, Cleaning & testing of T/C’S with T/W’S & Tagging. Restoration after T/M-II clearance.

DD. Removal, Cleaning, testing & restoration of LPT exhaust Hood T/C’S & RTD. Removal, Cleaning, testing, tagging & restoration after T/M-II Clearance.

EE. Disconnection of HP/IP stop & Control valves Limit switches & PFTS. Disconnection of HP/IP stop & Cv’s LS & PFT’s Restoration after T/M-II Clearance.

FF. Disconnection & removed of HP/IP ATT valves motors. Disconnection & Removal of ATT motors. Restoration after T/M-II clearance.

GG. Disconnection & removal of LPBP 1 & 2 stop control & water Injection Limit switches & PFT’S. Disconnection & Removal of Limit switches & PFT”S. Cleaning, testing & restoration after T/M-II clearence.

57

HH. I.P. inner casing TSE T/C – 4 Nos. Removal, testing and replacement Removal of T/C’S & replacement by new terted T/C’s.

II. Removal,Calibration and normalisation ,Retrofit-ting of main turbine turbovisory instru-ments and EHG unit.

Removal of existing instrument. Installation of new instruments. Made such facility so that Signal of instruments available upto panel.

JJ. Disconnection, removal, servicing of HPBP1, HPBP2, FOD-1 & 2, BPE1, BPE2, BD valve servo & Blocking element, both tank & suction filter cleaning.

Depressurization, disconnection of hoses & removal of servo/blocking element, servicing line & micro filter

Line filters removal & line flushing. Fresh oil top up, valves Calibration after T/M-II clearance & servo/ blocking unit restoration.

KK. Seal /leak off steam valve sump, Filter & Servo-unit Cleaning, Calibration, and Normalization. Sump oil removal, cleaning. Filter cleaning. Servo unit cleaning New oil top up Stroke with PFT calibration. Remote trial.

LL. Removal and Normalization of Turbine side instru-ments as per TM-II & EM–II requirement Supply isolation, connec-tion removal and cleaning. Restoration & trial after TM-II/EM-II Clearance.

MM. Removal, Cleaning, Calibration of HOT & Cold gas Primary water RTD’S/ Temp. Switches & Acw I/L/OL RTD’S

Supply isolation, dis-connection & instruments removal Cleaning, Calibration Restoration after T/M-II Clearance.

NN. Disconnection, Removal & restoration of Generator seal oil TE & EE RTD’S, Prechamber Level Probe Gas Cooler I/L & O/L RTD’S.

Supply isolation, dis-connection & instruments removal

58

Cleaning, checking & Calibration Restoration after T/M-II Clearance.

OO. Main Exciter Hot/Cold air instruments removal, Calibration & restoration as per TM-II schedule. Supply isolation, dis-connection & instruments removal Cleaning, checking & Calibration Restoration after T/M-II Clearance.

PP. Removal & Servicing of CRH NRV’s Limit switches assemblies LHS & RHS. Dis-connection & removal of LS assemblies. Servicing & testing Restoration after T/M-II Clearance.

QQ. Removal, Cleaning, Calibration of all Press. Switches, Press. Gauges,Temp. switches temp. gauges, transmitters, RTD’s of-

Dis-connection, removal Cleaning, checking & Calibrationi) Lub. Oil& Turbine drain oil system.

Repair / Replacement of defective instrumentsii) Control Fluid system.

Restoration after T/M-II Clearance.i. Governing racksii. LP bypass systemiii. HP bypass systemiv. Primary water systemv. Gas systemvi. Seal Oil system inclusive of new ckt.

RR. TDBFP A/B, MDBFP C/D , CEP A/B/C instruments checking, calibration and protection trials.

SS. Provision of PVC tubes for condenser hydraulic test & Hot-well level switches functional checking.

PVC tube to be provided as per requirements.

TT. LPH -1/2/3, GSC Level switches functional testing with Protocol with operation and TM-II

UU. TDBFP A & B Governing Characteristics & protection trial

59

VV. Governing Characteristics through EHC & Hydraulic with TM-II & operation

WW. LP bypass stop & CV’s with water injection valves remote trials.

XX. Turbine Protection trial. CPU all valves solenoid checking, trial & replacement if necessary. CPU bypass valve & DP transmitter calibration & interlock checking .

YY. CPU instrument air valves checking & replacement if necessary.

ZZ. SWAS room pH & conductivity meters sensors cleaning & ensuring availability of these signals on DCS.

AAA. All air heaters flue gas inlet thermocouple guide pipe provision

BBB. Sample isolating valves & blow down needle valves(Whitey make) replacement

TESTING SECTION

A. Generator relay testing by secondary injection & CT/PT resistance checking. Current relay testing

Voltage Relay Testing

Power Relay & frequency relay Testing

Impedance Relay Testing

PT fuse replacement and connection tightening

CT/PT Resistance measurement & connections Checking

Annunciations and SOE points checking

B. Generator Testing a Stator Rotor

Main & pilot execitor

60

diode and fuses

GCB Trial and Dynamic Testing of Generator

C. HT Switch gear Relays testing a Unit Board A Unit Board B Unit Board C

Unit Board D

Compressor Switch gear

Station Switch gear(11KV)

AHP switchgear

D. HT Circuit Breaker operation time & contact resistance measurement and connection tightening ( Unit Boards)

Unit Board A & B

Unit Board C & D

BTS A/B/C/D Trial

E. LT Switchgear Relay testing PA/EMPA board relay testing MA/ME/MD Board relay testing

AHP LT board relay Testing

mics works of HT/LT switchgear

PA/EMPA Auto changeover trial and DG set auto pick up trial

F. GTR / UAT Transformer testing, OTI/WTI calibration and. Protection trials. GTR R/Y/B Testing

UAT A/B/C/D Testing

SAT 4A/4B Testing

OTI/WTI calibration,and Mech.Protection trials

GTR WATER FLOW , oil pump trial

GTR Bushing

G. Checking of Battery Chargers. 220 V chargers

24 V chargers

UPS

Misc. works of Transformer side

61

Motorised valves

Bottom Ash panel/Air compressor panel

Services to operation and other sections and Misc. works

H. ODP WORKS CCW transformer testing

CTPA Relay Testing and connection tightening and reguler running work of ODP

CTFAN Panel checking and control room control panel checking/connection tightening

ODP RELAY TESTING WORKS

Regular and other ODP works

PART – II

ACTUAL OVERHAUL ACTIVITIES

WORKS CARRIED OUT DURING ANNUAL OVERHAUL OF UNIT # 5

BOILER MAINTENANCE

FURNACE

1. Ring headers orifices checking carried out. Screen fitting work carried out.

2. Drum internal inspection carried out.

a) FIRST PASS :1. Hydrojetting in WW, Divisional panel , wall reheater, PSH, RH, carried out.

2. Thickness survey at all elevation Water wall, Repeater (RHS) Repeater (LHS), Super heater (RHS)

Super heater (LHS) carried out. Damaged & eroded tubes cuttng and welding at all elevations of WSB

carried out.

3. Burner corner bend welding carried out.

4. DP & PSH repair work carried out.

5. Ash removal work in Pent House carried out.

6. Cat house and Dog house cleaning is carried out.

b) SECOND PASS :

1. Screen tubes inspection completed.

2. Economizer upper assy. repair work carried out

62

As per thickness survey conducted Furnace various tubes marking, Radiography, Repairs/replacement

carried out as follows

JOINT STATUS IS AS BELOW-

ZONE AGENCY EX.JONT MRKD JONT

JT. COMPL RADIOGRAPHY RAPAIR

WATER WALL SHEL 1500 878 878 878

ADORE 587 587 587

DIV PANEL SHEL 50 60 60 60

ADORE 48 48 48

PSH SHEL 250 23 23 23

ADORE 47 47 47

RE HEATER SHEL 50 4 4 4

ADORE 4 4 4

SCREEN TUBE BCC 50 4 4 4

VK

ECO(UPPER

ADDNL)

BCC 600 548 520 474

VK 532 532 481

63

LTSH BCC 500 536 536 536

VK 440 440 440

ECO (MIDD

&LOW REP.

SH VERT. SP.

ASSY REP.

STEAM

COOLED WALL

BCC 50

VK 14 14 14

RLA SHEL 100 83 82 82

TOTAL 3150 3808 3779 3682

c) ID FAN 5A, 5B, 5C & 5D :

1. Lube oil tank, filter and cooler cleaning work carried out.

2. DE & NDE side bearing inspection work completed. Bearing boxed up.

3. Cooler cleaning completed.

4. Impeller cleaning done.

d) FD FAN - 5A, 5B :

1. FD Fan 5B bearing inspection work completed.

2. FD Fan 5A DE side bearing replacement work completed.

3. Duct and Impeller cleaning done.

e) PA FAN -5A, 5B :

1. Bearing inspection work completed.

2. Impeller and IGV gate cleaning done.

3. Gate servicing done.

64

f) BURNER TILT :

1. Corner No. 1 –

Power cylinder servicing and wind box cleaning done.

All air buckets cleaned.

Tie rod servicing completed.

Burner compartment repairing work completed.

08 New coal nozzle assy. positioning done. Alignment completed.

Inner cover plate fitted.

2. Corner no. 2 –







3. Corner no. 3-







4. Corner no. 4 –

65







g) AIR HEATERS :

1. Air Preheater-5A :

I. Primary :

All old baskets replaced with new basket

Support and guide bearing inspection work carried out.

Support bearing replacement work completed.

Rotor and sector plate leveling completed.

Guide and Support bearing cooler cleaning done.

Gearbox insp. carried out. Hot & cold end radial seal setting done

II. Secondary :

All old baskets replaced with new basket

Support and guide bearing inspection work carried out.


Guide and Support bearing cooler cleaning done.

Gearbox insp. carried out. Hot & cold end radial seal setting done

66

2. Air Preheater-5B:

I. Primary :

All old baskets replaced with new basket.

Hot& Cold end side sector plates repairs works carried out.

Grating repairs’ work carried out.

Support and guide bearing inspection completed.

Guide and Support bearing cooler cleaning work completed.


Seal fitting work is in progress.

II. Secondary :

All old baskets replaced with new basket.

Hot& Cold end side sector plates repairs works carried out.

Grating repairs’ work carried out.

Support and guide bearing inspection completed.

Guide and Support bearing cooler cleaning work completed.


Seal fitting work is in progress.

h) AIR / GAS DAMPERS :

GD-1A, GD-1B servicing done. GD-2A, 2B servicing done. GD-3A, 3B servicing done. GD-4A1, 4A2 replaced by new one. GD-4B1,4B2 servicing done.

67

i) HP VALVES :

Following V/V’s servicing / repairing / replacement carried out

High Pressure valves—% completed

Sr Valve descriptions

Qty dismantling Machining Lapping Box up HANDOVERTO

I&C / TEST

1 MS VALVE 2 2 2 2 2

2 SH Spray control v/v

5 5 5 1

3 RH Spray control v/v

5 5 5

4 SH MANUAL ISO V/V

4 4 4 4

5 SH drain valve 10 10 10 10

6 Safety valve 16 16 16 8

68

7 Zero meter drain valve

8 8 8 8

8 RH MANUAL ISO V/V

4 4 4 4

9 RH SPRAY MOT ISO. VALVE

4 4 4 3

10 DRUM VENT 8 8 8 8 4

11 STARTUP VENT 4 4 4 4 4

12 PRDS STATION VALVE

3 1 1 1

13 SH SPRAY MOT ISO. VALVE

4 4 4 4 4

14 SB moto, man & CV

3 2 2 1

15

TOTAL 80 77 0 77 58 14

j) BCW PUMPS :

1. BCW pump cooler cleaning done

k) COAL MILLS :

I. COAL MILL – A :

1. Type-A overhaul carried out.

2. Air port assembly replaced

3. Air deflectors and vane wheel segment welding carried out.

4. Extension ring top plated welding carried out.

5. Inner seal air ring replaced.

6. Gear box side coupling replaced.

7. Hot air damper close/zero position done.

8. PA duct cleaning done.

9. Scrapper area cleaned.

69

II. COAL FEEDER - 5A :

1. Internal inspection carried out.

2. Bunker outlet gate and C/F inlet gate servicing done.

3. Rubber skirt fitting done.

4. Modification of COC base plate done.

5. Belt, pulley, bearings replaced.

6. G/B oil seal and stud plate modification work carried out.

III. COAL PIPE A :

1. Pipe and bend 2A1 replaced.

2. 4.5 mtr. pipe on duct and bend 45 degree replaced.

3. Centre pipe replaced, MOE A3, A2 and A4 replaced.

4. 4th corner second bend 2A4 and pipe 2m and 1 m long after and before respect replaced.

I. COAL MILL – B :


2. Center pipe replaced.

3. Ventury joint patch welding done.



6. 5 Nos. of ICP replaced.

7. Coal Mill Lube oil cooler cleaning done.

8. MOE B3 and MOE B2 replaced.

9. HAG/CAG servicing/ calibration done.

II. COAL FEEDER - B


70

2. Bunker outlet gate/inlet gate and C/F inlet gate servicing done.


4. Bunker outlet gate all stud roller replaced.

III. COAL PIPE - B :

1. Fire corner 1B2 pipe replaced.

2. Send pipe second corner after MOE 4.55 mtr. replaced.

3. 3ed pipe 3ed corner after MOE 1.900 mtr replaced.

4. 4th pipe 4th corner after MOE 6.700 mtr replaced.

5. 3ed corner 6th B3 pipe and 2 coupling and 3B3 bend at 9mtr level and 2B2 bend and pipe on duct

replaced.

6. MOE B2 replaced

7. 3ed corner on 9 mtr level 5.5 mtr pipe 6.2 mtr pipe and bend replaced.

I. COAL MILL – C :


2. CAD seal replaced.

3. Centre pipe replaced.

4. MOE C1 and MOE C3 replaced.

5. Inner seal ring replaced.



8. Lop cooler cleaning done

9. Inner coal leakages and ventury patching done.

II. COAL FEEDER - 5C :


71

2. C/F inlet and bunker O/L gate servicing done.

3. Rubber skirt fitting done

4. BOG/FOG bearing and sprocket shaft replaced.

5. COC base plate modification done.

6. Inlet skirt, side skirt, LH-RH 2 nos. extended skirt plate replaced.

7. Rubber belt with 2 nos. bearings replaced.

8. Gear box servicing done.

III. COAL PIPE C: 1. Centre pipe replaced.

2. C1 post pipe replaced

3. MOE C1, C4 and C3 replaced

4. 3ed pipe 3ed corner after MOE 1.700 mtr replaced.

5. Pipe on duct replaced.

6. C1 post pipe 2.7mtr replaced.

7. 1st corner 6.17mtr pipe replaced.

I. COAL MILL – D :


2. PA duct cleaning carried out.



5. MOE D3 replaced.

6. 1 nos. inner seal replaced.

7. Bowl hub skirt replaced.

8. Inner cone checked, found fallen in cone same was refitted.


II. COAL FEEDER – D :


72

2. C/F inlet and bunker o/l gate servicing done.


4. Belt replaced.

III. COAL PIPE D:


2. MOE D3replacd

3. 2nd bend 2D2 and 2nd pipe after 2D2 bend 1mtr replaced.

4. 4th pipe 4th corner 9.00mtr replaced.

5. 3ed corner 45 degree bend and 2.3mtr pipe (over mill) replaced.

I. COAL MILL – E :

1. Type-C overhaul carried out.

2. Bull ring segment replaced.

3. J/A-J2 and J3 replaced.

4. Vane wheel top plate clamping hard facing done.

5. Bowl hub cover top plate welding done.




9. Door liner replaced

10. Inner cone and ventury checked found worn out, patching and welding done.

73

II. COAL FEEDER - 5E :


2. Belt replaced.




6. Center skirt plate (inlet) replaced.

7. Support roller bearing and gear box oil replaced.

III. COAL PIPE E: 1. 1st pipe 1st corner after MOE 5.5 mtr. replaced.

2. 3ed corner after MOE 1.500mtr replaced.

3. 3ed corner 2E3 pipe and bend 30degree and 1.5mtr pipe replaced

4. 4th corner 1E4 replaced.

5. 1st corner MOE replaced.

6. 4th corner 4.2mtr pipe replaced.

7. 3ed corner 1.4 mtr pipe and 30 degree bend replaced.

8. MDV flap E1, E4 replaced.

I. COAL MILL – F :


2. Scrapper liner replaced.



5. Scrapper area cleaned

II. COAL FEEDER – F :




74

4. Belt replaced


6. Center skirt plate (inlet) and side skirt plate with rubber and extended skirt replaced.

7. Support roller bearing and support rollers replaced.

III. COAL PIPE F: 1. pipe 1st corner after MOE 2.400mtr replaced.

2. 1st corner 1.2mtr pipe after MOE and MOV replaced.

3. MDV flaps F1, F2, F3 replaced.

I. COAL MILL – G :

1. J1 AND J2 OIL REPLACED.



4. Lube oil cooler cleaning done.

5. MDV flap G1 and G3 replaced.

II. COAL FEEDER - G


2. C/F inlet and bunker O/L and I/L gate servicing done.


4. COC base plate modification done

5. Skirt plate center, LH-RH, extended modification done.

6. G/B servicing done

III. COAL PIPE G: 1. 2nd pipe 1G2 2nd corner 3.00mtr replaced.

2. 1st corner 2.4 mtr pipe and 30 degree bend after MOV replaced.

3. MDV flaps G1, G4 replaced.

75

I. COAL MILL – H :


2. MDV flap H3 and H4 replaced.

3. LOP filter and breather cleaning done.




II. COAL FEEDER – H :

1. Coal Feeder internal inspection done.

2. C/F inlet and bunker O/L gate servicing done.



5. Skirt plate with rubber replaced.

6. Rubber belt with support roller bearing replaced.

III. COAL PIPE H: 1. 1st corner 2.9mtr pipe and 1B1 bend, 2.4mtr pipe replaced.

2. MDV flaps H3 and H4 replacd.

l) CAG / CAD :

1. All mills CAG servicing done.

2. All CAD made free.

m) SEAL AIR FANS 5A & 5B :

1. Bearing internal inspection of both fans done.

2. Fan brg. Greasing done.

3. Suction filter cleaning carried out.

76

4. Damper servicing done.

n) ESP PASS - A, B, C, D :

1. Water washing carried out.

2. Inlet GD screen replacement work done.

3. All fields internal inspection done.

4. All fields damaged/worn out collecting plates, ERM / CRM top & bottom hammers, bearings, shock

bars, guide angles, pads & pin wheels repairs/replacement work carried out.

U = 5 E.S.P. PASS REPAIRED AND REPLACEMENT REPORT-

1. E.S.P. A PASS :

S.NO.WORK

DISCRIPTION1A1 1A2

2A1 2A2

3A1 3A2

4A1 4A2

5A1 5A2

6A1 6A2

TOTAL REMARK

1 C.R.M.Hammer

57 57 20 15 11 09 230 Replaced

2 C.R.M.Bearings

12 12 12 12 7 4 45 Replaced

3 Shock Pads 13 5 16 12 13 6 38 Replaced

4 Shock Bars 12 14 5 8 7 3 13 Repaired

5 C.R.M.Shafts

1 0 0 0 0 0 5 Replaced

6 C.R.M. 0 1 1 1 1 1 5 Alignment

77

Shafts

7 Guide Angles 10 0 0 30 10 7 78 Replaced

8 Guide Angles 0 12 12 0 0 0 52 Alignment

9Hoppers Gas Screens

0 2 0 0 0 0 2 Repaired

10 E.R.M.Hammers

56 56 13 20 17 18 233 Replaced

11 E.R.M.Bearings

29 24 18 12 12 12 98 Replaced

12 E.R.M.Shafts

10 0 0 0 0 0 0 Replaced

13 E.R.M.Shafts

1 1 1 1 1 1 6 Alignment

14 Pin Wheel Big 4 4 3 1 1 2 17 Repaired

15 Pin Wheel Small 4 4 7 6 0 0 19 Repaired

16 Bush Bearings 4 8 4 2 2 0 22 Replaced

17 Vertical Shafts 2 2 2 0 0 0 0 Replaced

18 Notching Of Plates 18 24 21 10 10 9 80 Repaired

19 Collecting Plates 36 8 8 3 60 0 2 Repaired

20 E.R.M.Electrodes

94

150

72

128

94 Replaced

21 "U"Clamps

150 Replaced

22 G.D.Screens

40 Replaced

23 Deflector Plates 128 Replaced

2. E.S.P. B PASS :

S.NO. WORK 1B1 2B1 3B1 4B1 5B1 6B1 TOTAL REMARK

78

DISCRIPTION 1B2 2B2 3B2 4B2 5B2 6B2

1C.R.M.

Hammer57 57 31 27 23 9 204 Replaced

2C.R.M.

Bearings12 12 14 12 3 3 56 Replaced



5C.R.M.

Shafts0 0 0 0 0 0 0 Replaced

6C.R.M.

Shafts1 1 1 1 1 1 6 Alignment




50 0 2 0 0 0 50 Repaired

10E.R.M.

Hammers56 56 56 31 32 21 202 Replaced

11E.R.M.


12E.R.M.


13E.R.M.





79




20E.R.M.

Electrodes 48

100

45

128

48 Replaced

21 "U"Clamps

100 Replaced

22 G.D.Screens

45 Replaced

23 Deflector Plates 128 Replaced

3. E.S.P. C PASS

S.NO.WORK

DISCRIPTION

1C1 1C2

2C1 2C2

3C1 3C2

4C1 4C2

5C1 5C2

6C1 6C2

TOTAL REMARK

1C.R.M.


2C.R.M.




5 C.R.M. 0 0 12 0 0 0 12 Replaced

80

Shafts

6C.R.M.





50 0 0 0 0 0 50 Repaired

10E.R.M.


11E.R.M.


12E.R.M.


13E.R.M.








20E.R.M.

Electrodes

25

100

50

100

25

21 "U"Clamps

100

22 G.D. 50

81

Screens

23 Deflector Plates 100

4. E.S.P. D PASS

S.NO.

WORK

DISCRIPTION

1D1 1D2

2D1 2D2

3D1 3D2

4D1 4D2

5D1 5D2

6D1 6D2

TOTAL REMARK

1C.R.M.


2C.R.M.




5C.R.M.


6C.R.M.





160 0 0 0 0 0 160 Repaired

10E.R.M.


11E.R.M.


12 E.R.M. 0 0 0 0 0 0 0 Replaced

82

Shafts

13E.R.M.








20E.R.M.

Electrodes 400

150

160

39

400

21 "U"Clamps

150

22 G.D.Screens

160

23 Deflector Plates 39

U = 5 E.S.P. PASS REPAIRED AND REPLACEMENT REPORT:

S.NO. WORK DISCRIPTION

E.S.P. A PASS

E.S.P. B PASS

E.S.P. C PASS

E.S.P. D PASS

TOTAL CONSUME REMARK

1C.R.M.

Hammer230 204 211 183 828 Replaced

2C.R.M.

Bearings45 56 65 46 212 Replaced

3 Shock Pads 38 51 66 74 229 Replaced

4 Shock Bars 13 48 40 49 150 Repaired

83

5C.R.M.

Shafts5 0 12 0 17 Replaced

6C.R.M.

Shafts5 6 6 6 23 Alignment

7 Guide Angles 78 57 50 60 245 Replaced

8 Guide Angles 52 3 0 0 55 Alignment

9Hoppers Gas Screens 2 50 50 160 262 Repaired

10E.R.M.

Hammers233 202 228 212 875 Replaced

11E.R.M.

Bearings98 107 120 108 433 Replaced

12E.R.M.

Shafts0 10 62 0 72 Replaced

13E.R.M.

Shafts6 63 40 34 143 Alignment

14 Pin Wheel Big 17 18 24 24 83 Repaired

15 Pin Wheel Small 19 18 24 48 109 Repaired

16 Bush Bearings 22 40 48 48 158 Replaced

17 Vertical Shafts 0 26 32 48 106 Replaced

18Notching Of

Plates 80 60 52 39 231 Repaired

19Collecting Plates 2 30 24 22 78 Repaired

20E.R.M.

Electrodes94 48 25 400 567 Replaced

21"U"

Clamps150 100 100 150 500 Replaced

22G.D.

Screens40 45 50 160 295 Replaced

23 Deflector Plates 128 128 100 39 395 Replaced

84

o) BOTTOM ASH HOPPER:

1. Seal trough cleaning done.

2. Seal trough corner and center C/M side leakage attended.

3. Seal trough inner side plate repaired.

4. Bottom ash hopper cleaning done.

5. Bottom ash hopper strengthening done.

6. Dome repairing done.

7. 50 N.B. line seal trough line and inspection glass flushing line replaced.

8. 100 N.B. seal trough filling header at seal trough header level and bottom ash flushing line 90 m and 9

m bend fabricated.

9. Damaged LP ash water pipe line 150NB replaced.

10. 200 N.B HP line 17 m and 5 bend replaced.

11. 178 tons refractory gun netting done.

12. 4 No. of surge box repaired.

13. Refractory cooling water line, hopper flushing line 100 NB replaced, 02Nos.bendfabricated.

14. Bottom ash refractory replacement works carried out.

15. 210 RMT M.S. welding done.

p) CLINKER GRINDERS AND ASH GATES:

1. C/G-1A and 1B, 2Ahyjector manual valve servicing done.

2. C/G-2B hyjector manual valve replaced.

3. C/G -1A, 1B, 2A, 2B ash feed gate repairing done.

4. C/G -1A, 1B, 2A, 2B feed chute hopper repair and welding done.

5. C/G -1A, 1B, 2A, 2B ash gate shaft gland replaced.

6. Flushing water valve 100 N.B. 02 replaced.

7. Feed Chute hard facing carried out.

85

8. All C/G ash feed gate indicating rod box repaired.

9. Discharge line, ground level up to bend replacement work carried out.

10. 200 N.B.3 valve replaced and 13 valve servicing done.

11. 100 N.B.3 valve replaced and 3 valve servicing done.

12. Seal water line 4 no of valve servicing done.

13. 4 no. of man door servicing done.

q) FLUE GAS DUCT :

1. All duct cleaning done.`

2. Ash &debris removed from duct.

3. Flue gas path damaged bracing replacement carried out.

4. Hot air duct damaged bracing replaced.

5. Worn out MS plate’s replacement done.

6. Cover plates of expansion joint replaced.

7. Damaged expansion joints at ESP outlets repairing work carried out.

8. Flue gas duct hoppers repairing work carried out.

9. Diversion plates at ESP inlet replaced.

10. PAH vertical duct has hole at 27 m level and hot air duct U # 5 side in front of ECO duct its corner

expansion joint bottom leaf found damaged same attended by patch welding

r) COARSE ASH EVACUATION SYSTEM :

1. All eco hoppers, duct hoppers cleaning carried out.

2. ECO hopper common discharge pipe 200 N.B.8 m replaced.

3. ECO hopper common vertical pipe 200 N.B.60 m replaced.

4. ECO hopper h. p. line damage pipe replaced.

5. All course ash distance piece fitting done.

6. Course ash hopper feeder ejector 22 no. servicing done.

7. 44 no. of air heater chain valve servicing and jamming removal done.

86

8. 18 no. of servicing water 100 N.B. done.



11. 2 no. of servicing of hyjector of C/A tank done.

12. 400 m2 hopper structure and pipe painting done.

13. 2 no. of course ash tank cleaning done.

14. Course ash hopper both side common slurry tank strengthening done.

15. 12 no. feeder ejector nozzle set replaced.

16. All eco hoppers, duct hoppers ash / chain v/v servicing carried out.

17. Eco hoppers trench repairs carried out.

s) FLY ASH EVACUATION SYSTEM :

1. Feeder ejector servicing done -72 no.

2. Ash valve and chain valve servicing done -144 no.

3. ESP all hoppers choke up removal done – 1 no.

4. Total welding done – 200 RMT

5. Replacement of pipe line 150 NB- 112 m

6. Servicing of water valve 350 NB - 4 no.



t) ESP INLET AND OUTLET GATE:

1) ESP A, B, C, D passes inlet gate both side gear box servicing done. Old oil replaced by fresh oil.

2) ESP A, B, C, D pass inlet gate support welding done.

3) ESP inlet gate 6A1, 6A2, 6B1, 6B2, 6C1, 6C2, 6D1, 6D2 manual trial found ok.

4) ESP outlet gate 7A, 7B, 7C, 7D manual trail taken found ok.

87

88

TURBINE MAINTENANCE

A) MAIN TG:

1) Seal oil Bearing DPT taken.

2) Generator Pressurization test completed at 6kg/cm2, leakage found in Bushing.

3) MOP bearing clearance correction done.

4) Governing- Hydraulic convertor, EHG Convertor servicing was done no abnormality seen.

a) HPT :

1) HPT Horn drop, Swing check, Roll check, CRO test, Bump test completed.

2) Alumina blasting carried out

3) HP rotor MPI Completed

4) Inner Casing quality taken.

5) HP rotor flow path taken

b) IPT: 1) IP-LP CRO Completed. Roll check taken.

2) Rotor Flow path completed

3) Rotor Alumina blasting completed

4) IPT rotor MPI was Completed

c) LPT: 1) LPT-Gen CRO completed. Roll check taken.

2) LPT flow path checking completed.

3) Alumina blasting done.

4) Free standing blades all MPI completed.

5) blade No 34 from 2L was found defective. Replaced with new blades.

6) NFT of free standing blades taken.

7) Inlet bellow found defective, replace with new bellow.

89

d) GENERATOR/EXCITER : 1) CRO & Swing check of Exciter & Generator Coupling taken.2) Exciter rotor leak test taken.3) Compressor assembly Blade rings inspection done.4) CC Bolt found leakage. Same was attended.5) Conical filters cleaning done.6) Pressurization of stator was carried out.7) Primary water magnetic filter cleaned.

B) TANK CLEANING:

1) Control fluid tank bucket strainer cleaning done.

2) Main Turbine MOT tank cleaning carried out.

3) 3 TDBFP-6A and 6B tank cleaned.

B) HP /LP VALVES:

1) HPCV 3 & 4 seat found damage.

2) HPBP valve 1 & 2 servicing done.

3) HPBP 1 & 2 servo motor servicing done.

4) LPBP-1, 2 valve servicing done.

5) LPBP spray valve V1, V2, V3, V4 servicing carried out.

6) BPE-1 &BPE-2 valve servicing done.

7) BPE 1 & 2 servo motor servicing done.

8) BD valve servicing done

9) BD isolating valve servicing done.

C) CONDENSER :

1) Cleaning work completed.

2) Installation of Cathodic protection completed.

3) End Plate coating work completed.

4) Condenser gravity test completed

D) BOILER FEED PUMPS :a) TDBFP 5B1) Turbine overhaul done.

2) Rotor sand blasting done.

90

3) Cartridge replacement done.

E) CEP -5A:

1) Mechanical Seal servicing completed.

G) HP HEATERS:

1) HPH 5A, 5B, 6A & 6B internal inspection Carried out and air leak test taken.

H) LP HEATERS :1) LPH 1, 2 & 3 internal inspections carried out.

2) LPH 2&3 Air leak test Carried out & found normal. No leakage found.

I) MS AND HRH STRAINERS :1. All MS strainer servicing done. Bonnet seal ring replaced by new one.

2. All HRH strainer servicing done. Bonnet seal ring replaced by new one.

J) DEAERATOR AND FST :1. Deaerator & FST internal insp. carried out.

2. Damaged nozzles replaced with new.

K) COOLERS : 1. Exciter cooler (2 Nos.) Cleaning / brushing / flushing / cleaning done.

2. Exciter cooler (4 Nos.) ACW valve internal inspection & servicing done.

3. Hydrogen coolers (4 Nos.): Acid / brushing / flushing / cleaning done.

4. H2 coolers- 4 Nos. of ACW outlet valve & 2 Nos. of inlet valve servicing done.

5. H2 cooler temperature control valve servicing done.

6. Primary water cooler- 3 Nos. of valves internal inspection & servicing done.

7. Primary water cooler- 3 Nos. Cleaning/ brushing /flushing carried out.

8. Primary water cooler temp. Control valve servicing done.

9. Seal oil cooler both air side &hydrogen side cleaning/ brushing /flushing carried out.

10. Seal oil rack ACW VALVE servicing done.

11. GTR R Y B Phases both coolers cleaning/ brushing /flushing Carried out.

12. GTR R Y B Phases coolers ACW valve servicing work Carried out.

13. GTR R Y B Phases ACW strainers cleaning done.

14. MOT coolers brushing / flushing / cleaning done. Air test taken at 6.0 kg/cm2.

15. Both MOT coolers ACW Inlet & Outlet valve servicing done.

91

16. FRF both coolers cleaning carried out both cooler gasket replaced.

17. FRF cooler temp control v/v servicing done

18. TDBFP 6A & 6B - Both oil coolers cleaning/ brushing /flushing carried out.

19. TDBFP6A And 6B Both oil coolers ACW Inlet & Outlet valve servicing done

20. MDBFP-6C, Lub oil coolers and working oil cooler ACW Inlet & Outlet valve servicing done.

21. MDBFP-6C, Lub oil & Working oil cooler brushing / flushing done.

22. MDBFP-6D, Lub oil coolers ACW Inlet & Outlet valve servicing done.

23. MDBFP-6D, Lub oil & Working oil cooler cleaning / brushing / flushing done.

STATUS OF COOLER ACW VALVES

STATUS OF HP VALVES

11

Valves Details Category

Valves for Servicing

Replacement of valves

Remark

1 TDBFP 5A S/H iso Gate Valve

Boxup done.

2 TDBFP 5A R/H iso Gate Valve

Boxup done.

3 TDBFP 5B S/H iso Gate Valve

Boxup done.

4 TDBFP 5B R/H iso Gate Valve

Boxup done.

5 MDBFP 5C S/H iso Gate Valve

Boxup done.

6 MDBFP 5C R/H iso Gate Valve

Boxup done.

7 MDBFP 5D R/H iso Gate Valve

Boxup done.

8 MDBFP 5D S/H iso Gate Valve

Boxup done.

9 MDBFP 5C R/H NRV NRV Boxup done.

10

MDBFP 5C S/H NRV NRV Boxup done.

11

MDBFP 5D S/H NRV NRV Boxup done.

12

MDBFP 5D R/H NRV NRV Boxup done.

13

TDBFP 5A R/H NRV NRV Boxup done.

14

TDBFP 5A S/H NRV NRV Boxup done.

15

TDBFP 5B R/H NRV NRV Boxup done.

16

TDBFP 5B S/H NRV NRV Boxup done.

17

TDBFP 5A Suction Gate Valve

Boxup done.

18

TDBFP 5B Suction Gate Valve

Boxup done.

92

19

MDBFP 5C Suction Gate Valve

Boxup done.

20

MDBFP 5D Suction Gate Valve

Boxup done.

21

TDBFP 5B Discharge Iso

Gate Valve

Boxup done.

22

TDBFP 5B Discharge NRV

NRV Boxup done.

23

BPE1 NRV NRV Boxup done.

24

BPE2 NRV NRV Boxup done.

25

CD 22 Globe Boxup done.

26

BD Isolating Valve Gate Boxup done.

27

CD 17 Globe Boxup done.

28

EX 02 Gate Boxup done

29


30

EX 03 Gate Boxup done.

31


32


33


34


35

AS 13 Gate Boxup done.

36


37

DR 11 Globe Boxup done.

38

DR 27 Globe Boxup done.

39

Mal 11 Globe Boxup done.

40


41


42


43


44


45


46


47


48

HR 115 Globe Boxup done.

93

49


50

MS 104 Globe Boxup done.

51


52


53


54


55

HR 502 Globe Boxup done

56


57


58

HR 508 Gloe Boxup done.

Operating Mode Quantity Completed

Motorized 23 23

Manual 23 16

Pneumatically 1 1

Hydraulically 0 0

NRV 11 11

Total 58 53

DEPARTMENTAL

1. DR 17,25 Bonnet leakage attended

2. All BFP RC line NRV Servicing completed.

3. Vacuum pump A & B Gland replacement done.

4. DR 32 Valve servicing completed.

5. EX 31 & 32 Diaphragm replaced& Seal inspection is in progress.

6. CEP RC Valves inspection.

7. HPBP Bladder replacement work.

94

ODP SECTIONA. AHP : 1. HP-LP ASH WATER PUMP VALVE SERVICING –completed.

2. Line A – 500NB B/F SERVICING completed.

3. Line B – 500NB B/F SERVICING completed.

4. Tank inlet- 350NB B/F SERVICING completed.

5. Tank inlet- 500NB B/F SERVICING completed.

6. Sump make up main isolating Valve servicing completed.

7. B/A & F/A Sump selection valve servicing completed.

8. Seal water line B-series replacement completed.

9. Seal water line A-series replacement completed.

10. Seal water suction header replacement completed.

11. Flushing line to A, B & C sump adding completed.

12. HPSWP-1,2 & LPSWP-1,2 Preventive maint. completed.

13. HPAWP-2 O/H completed.

14. 5CSDP-1 O/H completed.

15. 5ASDP-1 OH WIP.

16. Raw water tank cleaning.

17. Ash water tank cleaning completed.

B. SUMP CLEANING WORK : 1. 5B Sump cleaning completed.

2. 5A sump cleaning completed.

3. 5C sump cleaning completed.

C. OIL COOLER CLEANING: 1. B SERIES completed.

2. A SERIES completed.

D. ADL: 1. 5BSDP-4 bend to bend pipe replaced.

2. 5BSDP-4 bend to bend no.1 pipe replaced.

95

3. 5BSDP-3 expander to bend pipe replaced.

4. Pipe rotation done from CP. -4 to CP. 19.

5. Slope pipe replaced at CP. 21.

6. 5BSDP-2 horizontal pipe replaced.

7. 5B pipe replacement from CP.422 backward to CP.419 completed.

8. 5BSDP-2 vertical pipe replacement completed.

9. 5B slope pipe replacement at CP.-33 completed.

10. 5BSDP-4 discharge pipe replaced.

11. 5B sump suction pipe & suction bend replacement completed.

12. 5B pipe replacement from CP.414 to CP.419 completed.



15. 5B pipe replacement in pump house -pump s/c valve to reducer completed.



18. 5BSDP-2 vertical & horizontal pipe replacement completed.




22. 5A suction pipe replacement completed.

23. 5A suction bend re-irection completed.

24. 5A pipe rotation from CP 90 to CP 95 completed.

25. 5C suction pipe at sump replacement completed.


27. 5B pipe replacement from CP.472to CP.477 completed.

28. 5A & 5B pipe replacement -44 to -43 completed.

29. 5C suction pipe replacement completed.

30. 5C suction bend re-irection completed.

31. 5A ASDP-2 horizontal pipe repl. completed.

32. 5C suction valve to reducer pipe repl. completed.

33. 5A pipe replacement CP -40 to CP -38 completed.

34. 5B pipe replacement CP -30 to CP -23 completed.

96

35. 5B pipe replacement CP 319 to CP 313 completed.

36. 5B pipe replacement CP.593 to CP.595 completed.

E. CT FAN: 1. CT Fan 5A/1, 5A/5, 5B/1, 5B/6-O/H completed. 5B/1 trial pending.

2. CT Fan 5B/5- Blade repl. (5A/7, 5B/5, 5B/8 completed).

3. CT 5A nozzle cleaning completed.

5. CT 5B nozzle cleaning completed. (5B/1, 5B/2, 5B/3, 5B/4, 5B/5 completed)

6. CT 5A- Hot water basin Cleaning completed.

7. CT 5B- Hot water basin Cleaning Completed.

8. Riser valve sericing / repl. completed. (5A/1,2,3,4 Padmapur side & 5A/1, 3, 4, 6, 7, 8

chandrapur completed.) (Valve servicing completed.)

9. CT 5B-Riser valve sericing / repl. completed. (5B/2,4,7 Chandrapur side & 5B/4, 5, 6

Padmapur side repl. completed)

10. CT Fan 5A fan splash bar cleaning .(Padmapur & chandrapur side completed)

11. CT Fan 5B fan splash bar cleaning complted .

12. CT Fan 5A- broken hot water pipe replacement completed.

13. CT Fan 5B- broken hot water pipe repl. completed.

F. ACW / CCW PUMP : 1. ACW /CCW sump cleaning completed & strainer repairing / cleaning completed.

2. CCW-5C column pipe inspection & BFV servicing completed.

3. CCW-5D column pipe inspection completed. BFV servicing completed. Expansion joint repl.

completed.

4. CCW-5B BFV servicing completed.

5. CCW, ACW-thrust bearing oil replacement completed.

6. ACW-gland repl. completed.

7. CCW-5A, 5B gland repl. completed.

8. CCW-power pack oil replacement completed.

9. ACW line separation from CCW hot water line-completed.

10. Interconnection of existing CCW pipeline to CT 5C-completed

11. ACW underground line leakage-Attended.

97

G. SUMP MAKE UP, ACW, CCW, R-C VALVE SERVICING WORK 1. ACW air vent valve on disch. side servicing completed.

2. CCW air vent valve on disch. side servicing completed) bend replaced.

3. ACW R/C valve servicing 4nos. completed.

4. ACW return line drain valve 2 nos. servicing completed.

5. Sump make valve 2 no. servicing completed.

ELECTRICAL MAINTENANCE II

A) GENERATOR: 1. Exciter current carring bolt found leakage,same leakage attended.

2. Stator weidge tightness works done. Rotor wedge tightning carried out. Hydrogen compressor hub ir

value checked

3. Genertor stator winding hydraulic test along with bushings and phase connectors carried out. Leakage

at B phase bushing and stator inlet pressure valve found, leakage rate was 2 kg/cm2 per 24 hours,

same was attaneded. Generator stator IR value taken. IR value is in the range of 280 to 300 kohms.

4. Exciter rotor leakage test taken after attending c.c. Bolts leakage. 0.5 kg/cm2 n2 pressure drop

observed in 6 hrs.

5. Exciter air gaps checked

B) BATTERY CAPACITY TEST DURING COH-2015:

Sr.

No.

Battery Set

Name

Work Carried out Voltage (After Test)

Sp. Gravity (After Test)

Battery CapacityStart Stop

1Battery Set No. 1

01.01.16 02.01.16 246 Volts 1220 -1230 >100%

2Battery Set No. 2

04.01.16 07.01.16 246 Volts 1220 -1230>100%

3UPS Battery Set

12.01.16 19.01.16 243 Volts 1220 -1230>100%

98

G1 Battery Set

4

+24 V G1 Set23.01.16 24.01.16 28 Volts1 200-1205 >100%

-24 V G1 Set1 Damage cell found as per EXIDE battery, no capacity test was taken

G2 Battery Set

5

+24 V G2 Set17.01.16 18.01.16 28 Volts1 200-1205 >100%

-24 V G2 SetCleaning carried out, desulphation done, and battery charged

C) LT TRANSFORMERs COH-2015:

99

Sr.No. NAME OF TRANSFORMER

DATE OF P/M

1 LXB1 20.01.2016

2 LXA2 21.01.2016

3 XA 20.01.2016

4 XB 15.01.2016

5 OXA1 20.01.2016

6 OXA2 21.01.2016

D) HT TRANSFORMER WORK DURING COH-2015: 1. GTR – 5R:- Transformer testing and oil filtration, oil leakage attending, cleaning and painting.

2. GTR– 5Y:- Transformer testing and oil filtration, oil leakage attending, cleaning and painting.

3. GTR – 6B:- Transformer testing and oil filtration, oil leakage attending, cleaning and painting.

4. UAT – 5A:-Transformer testing and oil filtration, oil leakage attending, cleaning and painting.

5. UAT -5B:-transformer internal inspection, gasket and oil seal replacement, testing, cleaning and

painting carried out.

6. UAT – 5C:-Transformer testing and oil filtration, oil leakage attending, cleaning and painting.

7. UAT – 5D:- transformer internal inspection, gasket and oil seal replacement, testing, cleaning and

painting carried out

8. SAT – 3A:-Transformer oil filtration, testing carried out.

9. SAT – 3B :-Transformer oil filtration, testing carried out.

E) BUSDUCT INSPECTION COH-2015

All above bus cleaning

work carried out as a preventive measure. Also 21KV Bus duct inspection carried out during COH-

2015, No abnormality found.

100

Sr.No.

NAME OF BUS

1 BUS OF UNIT BOARD 5A TO STN. BOARD SE 13

2 BUS OF UNIT BOARD 5A TO UAT A

3 BUS OF UNIT BOARD 5B TO STN. BOARD SE 15

4 BUS OF UNIT BOARD 5B TO UAT B

5 PT CUBICAL(GENERATOR)

6 BUS OF UNIT BOARD 5D TO UAT D

7 BUS OF UNIT BOARD 5D TO STN. BOARD SE 12/2

8 BUS OF UNIT BOARD 5C TO UAT C

F) PREVENTIVE MAINTENANCE OF HT MOTOR COH U # 5:

G) OVERHAUL / PREVENTIVE MAINTENANCE OF LT MOTOR COH-2015 :

101

Sr.No. NAME OF HT MOTOR OVERHAUL / P/M

1 ID FAN-5A Overhaul

2 ID FAN-5B PM

3 ID FAN-5C PM

4 ID FAN-5D Overhaul

5 CEP 5A PM

6 CEP 5C PM

7 BCW 5A PM

8 BCW 5B PM

9 BCW 5C PM

10 FD FAN 5A PM

11 FD FAN 5B Overhaul

12 PA FAN 5A Overhaul

13 PA FAN 5B PM

14 COAL MILL 5A Overhaul

15 COAL MILL 5B Overhaul

16 COAL MILL 5C PM

17 COAL MILL 5D PM

18 COAL MILL 5E PM

19 COAL MILL 5F Overhaul

20 COAL MILL 5G PM

21 COAL MILL 5H PM

22 MDBFP-5C PM

23 MDBFP-5D PM

24 ASDP 1 2 3 4 PM

25 BSDP 1 2 3 4 PM

26 CSDP 1 PM

Sr.No. NAME OF LT MOTOR Work

1 SEAL AIR FAN 5A O/H

2 SEAL AIR FAN 5B O/H

3 SEAL OIL PUMPAIR SIDE 1 MOTOR REPLACED

4 SEAL OIL PUMP AIR SIDE 2 O/H

5 PAH 5B S/B MOTOR O/H

6 PAH 5B MAIN MOTOR O/H

7 PAH 5AMAIN MOTOR O/H

8 PAH 5A S/B MOTOR O/H

9 CONTROL FLUID 5A O/H

10 CONTROL FLUID 5B O/H

11 BCW BOOSTER NO.1 O/H

12 BCW BOOSTERNO.2 O/H

13 CLINKER GRINDER 1A O/H

14 CLINKER GRINDER 1B O/H

15 CLINKER GRINDER 2A O/H

16 CLINKER GRINDER 2B O/H

17 VACUUM PUMP 5B PM

18 MOT AOP-1 O/H

19 MAIN JOP AC O/H

20 DC SEAL WATER PUMP 1 & 2 PM

21 IAC-5A, B, C PM

22 TDBFP-5A-AOP-1 & 2 O/H

23 TDBFP-5B-AOP-1 & 2 O/H

24 HP AWP-1 & 3 PM

25 MDBFP-5C AOP O/H

26 MAIN DC JOP PM

27 C/M LOP – 5 C, D, G, H PM

28 C/F- 5A, B, C, F PM

29 AC SCANNER O/H

30 SAH-5A MAIN O/H

31 SAH-5B MAIN O/H

H) REVENTIVE MAINTENANCE OF BOARDS in COH U # 5:

Sr. No. NAME OF BOARDS

1 UNIT BOARD-5A

2 UNIT BOARD-5B

3 UNIT BOARD-5C

4 UNIT BOARD-5D

5 UNIT BOARD-5E

6 5MB BOARD

7 5MC BOARD

8 5MD BOARD

9 5ME BOARD

10 5MF BOARD

11 5MG BOARD

12 SOOT BLOWER BOARD

13 EMPA SECTION -I

102

13 EMPA SECTION -II

14 PA SECTION -I

15 PA SECTION-II

16 STATION BOARD INCOMER BREAKER

17 ESP A PASS LT BOARD

18 ESP B PASS LT BOARD

19 ESP C PASS LT BOARD

20 ESP D PASS LT BOARD

21 AHP HT SECTION-I

22 AHP HT SECTION -II

INSTRUMENTATION AND CONTROL

1. ALL HAG SOLENOID SERVICING DONE.

2. C/M DP S/W’S CALIBRATED.

3. BURNER TILT ALL INST. SERVICING DONE

4. FRF TANK LVL. S/W CALIBRATED

5. ALL C/M SEAL/PA DP S/W’S IMPULSE LINE FLUSHING DONE

6. ALL C/M SEAL/PA DP JB CLEANING DONE

7. SADC P/C AND POSITIONER SERVICING DONE

8. C/M THRUST PAD RTD, SEAL AIR V/V CHECKING AND TRIAL TAKEN. LUB. OIL SYSTEM

PRESS. S/W AND GAUGESCALIBRATION DONE

9. MOT LVE S/W’SCALIBRATED

103

10. ESP PASS, ECONOMISER DUCT HOPPER ASH V/V POWER CYLINDER AND SOLENOID

SERVICING DONE.

11. ID – A TO D SUCTION/DISCHARGE PRESSURE TRANSMITTERS IMPULSE LINE FLUSHING

DONE

12. PA FLOW TRANSMITTERS CALIBRATED

13. REJECT GATE & HAG GATE SERVICING DONE & TRIAL TAKEN.

14. ID – A TO D JB CLEANING DONE.

15. ESP ASH valve POWER CYLINDER AND SOLENIED SERVICING AND TRIAL TAKEN.

16. SECONDARY AIR FLOW TRASNMITER AND FURNACE PRESSURE TRANSMITTER

CALIBRATION DONE.

17. PA HEADER PRESSURE SWITCHES CALIBRATED

18. C/M A, B, C LOP PRESS. S/W’S CALIBRATED AND RESTORED.

19. ALL A/H,FURNACE DRAFT PRESSURE/DP TRANSMITTERS IMPULSE LINE FLUSHING DONE

20. FURNACE PRESSURE SWITCHES CALIBRATED.

21. FUR /WB, A /H FG DP TRANSMITTER CALIBRATED.

22. ELEATION CORNER SOLENOID AND HAG SOLENOID REPAIR/SERVICING DONE

23. ESP- ASH VALVE SEAL KIT REPLACED WITH NEW ONE. ESP MAIN WATER V/V P/C REPLACED

WITH HEALTHY P/C SINCE OLD ONE was PASSING.

24. FIRST STAGE PRESS. TRANSMITTER AND THROTTLE PRESS. TRANSMITTER CALIBRATION

done.

25. ALL IGNITOR ASSEMBLY SERVICING COMPLETED.

26. HP BYPASS SYSTEM BP-1&2, FOD-1&2, BD V/V SERVO/SOLENOID V/V SERVICING done.

27. MAIN TURBINE L.O. SYSTEM PRESS. S/W’S, HPCF PUMP PRESS S/W’S calibrated. SEAL OIL

SYSTEM PRESS. S/W CALIBRATION done.

28. BOTTOM ASH P/CSERVICING done.

29. ID FAN-A, B, C, D PRESS. S/W’S CALIBRATED.

30. SEAL OIL SYSTEM PRESS S/W’S CALIBRATED.

31. IPT OUTER CASING T/C, HPT CASING T/C AND IPT CASING CHECKING DONE

32. HPSV AND IPSV LIMIT SWITCHES REPAIRING/ CHECKING DONE.

33. INST. AIR DRIER P/C CHECKED, FOUND PASSING, REPAIR WORK done.

34. C/M LRG & TIG P/C CHECKING DONE.

35. FLAME SCANNER SERVICING done.

36. ALL A/H JB AND TRB CLEANING AND IMPULSE LINE REPAIR WORK done.

37. ID FAN A, B, C, D LO FILTER DP S/W’S CALIBRATED.

104

38. DEAERATOR SHELL PRESS. TRANSMITTER, CONDENSATE FLOW TO DEAERATOR

TRANSMITTER, DM MAKEUP FLOW TRANSMITTER, SEAL STM. HDR PRESS. TRANSMITTER

CALIBRATED.

39. C/M CONTROL DAMPER CALIBRATED.

40. HPCV & IPCV LIMIT S/W’S SERVICING AND REPAIRING DONE.

41. GEN. LIQUID LEVEL DETECTOR, LLD CHECKED FOUND HEALTHY

42. FD FAN-A IGV ACTUATOR MOTOR CHECKED

43. SEC. AIR FLOW AEROFILE (LEFT SIDE) FLUSHING DONE.

44. HP BYPASS SYSTEM SERVO VALVE LINE FLUSHING DONE.

45. INST. AIR DRIER EXHAUST V/V (SV3) P/C SEAL KIT REPLACED.

46. BOTTOM ASH P/C SEAL KIT REPLACEMENT WORK DONE.

47. SEC. AIR FLOW AEROFILE (RIGHT SIDE) FLUSHING DONE.

48. IPT INNER CASING T/C REMOVED.

49. PRIMARY WATER PUMP PRESS. S/W’S CALIBRATED AND RESTORED.

50. BFP-A, B, C, D SUCTION FLOW TRANSMITTER, CEP DISCHG. FLOW TRANSMITTER

CALIBRATED.

51. DAS PEM PACKAGE VALIDATION AND DAS CONTROLLER CHECKING WORK CARRIED OUT.

PEM PACKAGE OUTPUT REPORT SEND TO POG FOR VALIDATION.

52. CEP DISCHG. FLOW TRANSMITTER, CONDENSOR VACCUM TRANSMITTER CALIBRATED.

53. SEAL STEAM SYSTEM MAW-10, 50 V/V FILTER CLEANING, and OIL TOP UP DONE.

54. C/M D MILL O/L T/C AND ITS CABLE REPLACED WITH NEW ONE.

55. GEN. EXCITER TEMP. S/W’S CALIBRATED.

56. HOTWELL LEVEL VERY LOW S/W’S HEALTHINESS CHECKED FOUND OK.

57. GEN. EXCITER TEMP. S/W’S CALIBRATED.

58. S/H & R/H FLOW TRANSMITTER, FEED WATER FLOW TRANSMITTER CALIBRATED.

59. DR-17, 25 V/V INST. CALIBRATED.

60. O2 IN FG (LEFT AND RIGHT SIDE) PROBE INSPECTION, CLEANING AND CONNECTION

TIGHTENING CARRIED OUT.O2RIGHT SIDE PROBE SHIELD FOUND WORN OUT, SAME IS

REPAIRED BY PATCH WELDING.

61. HP BYPASS SYSTEM SERVO V/V SERVICING/REPAIRING DONE.

62. C/M HOT AIR GATE TRIAL TAKEN AND FEED BACK LIMIT SWITCHES CHECKED. 03 NOS.

FEED BACK LIMIT SWITCHES FOUND MALFUNCTIONING; ITS REPAIR WORK DONE.

63. ID FAN-A, B, C, D DISCHG. PRESS. TRANSMITTER CALIBRATED.

64. DR-39, 43 AND DM-2, 17, 21 V/V INST. SERVICING AND CALIBRATION DONE.

65. DEAERATOR LVL.TRANSMITTER CALIBRATED.

105

66. SADC POSITIONER CALIBRATED.

67. “A” SERIES SUMP LVL SENSOR SERVICED AND REPAIRED.

68. CD-81, 85, MDBFP-D R/C V/V INST. SERVICING AND CALIBRATION DONE.

69. MAIN TURBINE STARTING DEVICE LIMIT SWITCHES SERVICING DONE.

70. MAIN TURBINE GOVERNING RACK PRESSURE GAUGES CLEANING AND CHECKING DONE.

03 NOS. FAULTY GAIGES REPLACED WITH NEW ONE.

71. MAIN TURBINE JOP LINE PRESSURE GAUGES (03 NOS.) REPLACED WITH NEW ONE.

72. FSSS PANEL BNC CONNECTOR TIGHTENING CARRIED OUT.

73. BFP-A, B, C R/C V/V INST. SERVICING, NORMALISATION AND CALIBRATION DONE.

74. DR-32 V/V CALIBRATED.

75. GENERATOR PRE CHAMBER LLD AND RTD RESTORED.

76. MDBFP-C,D R/C V/V REMOTE TRIAL TAKEN.

77. MAIN TURBINE TSE SYSTEM T/C (50% AND 100%) CHECKING DONE.

78. MAIN TURBINE SPEED PROBE CHECKING CARRIED OUT.

79. FD-49 P/C SEAL KIT REPLACED AND V/V CALIBRATED.DR-6,13 V/V INST. SERVICING AND

CALIBRATION DONE.

80. BOILER STM. O/L PRESS. TRANSMITTER ,GEN. MAIN BUSHING FLOW TRANSMITTER

CALIBRATED.

81. FSSS FLAME FAILURE TRIP LOGIC ALL ELEVATION “ELEVATION 2/4 FLAME” INPUT

SIGNAL RELOCATED(DISTRIBUTED) IN TWO I/P CARDS (EARLIER SIGNAL IS INPUTTED

THROUGH SINGLE I/P CARD) AND ACCORDINGLY PROGARM IS MODIFIED.

82. HPCF TEMP. CONTROL V/V CALIBRATION DONE.

83. GEN. MAIN BUSHING FLOW TRANSMITTER AND STATOR WATER FLOW TRANSMITTER

CALIBRATED.

84. FD FAN-5B FAN BRG NDE SIDE RTD FOUND FAULTY, REPLACED WITH NEW ONE.

85. PA FAN-5A 01 NOS. JB FOUND RUSTED AND DAMAGED, SAME IS REPLACED WITH NEW

ONE.

86. OHP R/C V/V HO-11 & LO-11 INST. SERVICING AND CALIBRATION DONE.

87. 02 NOS. DAS CONTROLLER (REMAINING FAULTY CONTROLLER) CHECKED , 01 NO. DAS

CONTROLLER REPAIRED AND PUT IN SERVICE.01 NO. DAS CONTROLLER

MOTHERBOARD FOUND FAULTY.

88. MAIN TURBINE IPT BOTTOM CASING T/C (04 NOS) HEALTHINESS CHECKED,FOUND OK. ITS

CABLE DRESSING DONE.

89. HPBP SYSTEM OSU-1 ACUUMULATOR N2 GAS FILLING DONE. OSU-2 ACUUMULATOR N2

GAS FILLING DONEAAFTEWR BLADDER REPLACEMENT.

106

90. HPBP SYSTEM FOD BOTH ACCUMULATOR BLADDER FOUND PUNCTURED.

91. DR-02,,09,21,29,32 V/V INST. SERVICING AND CALIBRATION DONE.

92. HOT WELL TRANSMITTER CALIBRATION CARRIED OUT.

93. FD FAN-5A MOTOR ALONG WITH DRIVE CHECKED, MOTOR FOUND HEALTHY.

.

TESTING II

A) GENERATOR:

1. Generator Protection Panel Micom Relay testing.

2. Generator PT fuses replacement.

3. Generator Stator, Rotor, Main exciter, Pilot exciter – IR and Winding Resistance.

4. Exciter Diode Wheel diodes and Fuses checking.

5. Generator, GTR and UAT— protection/metering CT resistance measurement.

6. GCB ON/OFF and protection Trip Trial from PCR in co-ordination with 400KV GCR.

7. Unit Switchgear A, B, C and D – Incomer, Tie I/C and outgoing feeder Relay testing

8. Generator Rotor Earth Fault (REF) protection, CarbonBrush holder assembly internal wiring checking

9. Generator Dynamic testing completed at 0055 Hrs on 30.01.2016 and unit synchronized at 02.06.Hrs

on 30.01.2016.

Gen. Stator Resistance by TRM 104 using LR Meter wires:

R1-R2 resistance Y1-Y2 resistance B1-B2 resistance

1.694 mΩ 1.581 mΩ 1.589mΩ

B) GENERATOR ROTOR :

a) Gen. Rotor IR

Rotor IR values taken at ambient temp. = 32.00 C by 250 V Megger = > 50 MΩ

107

b) Gen. Rotor Resistance

Rotor winding resistance by LR 205 micro ohmmeter= 113.61 mohm and

Ambient temperature 320C

c) Gen. Rotor Impedance (Taken by Single phase Variac 15amp range)

Sr.

No.

AC volt applied Current in Amps.

V/I

Impedence

Freq.

Hz

1 10.35 2.99 3.461 49.96

2 20.45 5.96 3.431 49.96

3 30.43 8.79 3.461 49.97

4 40.23 11.59 3.471 49.99

5 45.06 12.93 3.484 49.95

Megger after rotor imp test > 50 MΩ

C) MAIN EXCITOR :

a) Exciter Upper & lower half field winding

Excitor Field Winding LOWER & UPPER Half Connected to each other

Megger value by 250 V Megger > 50 Mohm

Resistance by LR 205 Meter = 540 mohm ( Temp = 320 C )

b) Exciter Stator resistance

Main Exciter Armature Windings

R - Y 0.218 mohmMeasured at + Ve Wheel side

( + Ve WHEEL Towards Exciter )Y - B 0.214 mohm

B - R 0.226 mohm

Main Exciter Armature Windings

TEST RESULT OF GEN. TESTING (STATOR, ROTOR, EXC, PILOT EXC. & CAPA.

108

Main Excitor Armature Windings

R - Y 0.220 mohmMeasured at -- Ve Wheel side

(- Ve WHEEL Towards Generator )Y - B 0.222 mohm

B - R 0.225mohm

c) Exciter IR Values

A) Megger By 250 V Megger : Neutral To Shaft > 50 Mohm

B) Megger By 250 V Megger : + Ve Wheel To

- Ve Wheel = 0 Mohm ( Rev.Bias)

C) Megger By 250 V Megger : + Ve Wheel To - Ve Wheel => 50 Mohm (Forward Bias)

D) + Ve Wheel To Body > 50 Mohm

E) - Ve Wheel To Body > 50 Mohm

d) Quadrature coil

Quadrature Coil Res. Measurement IR Value

A) COIL 1 :Resi. By LR 205 Meter = 7.3 OHM (Temp = 320 C ) IR > 50 Mohm

B) COIL 2 :Resi. By LR 205 Meter = 7.3 OHM (Temp = 320 C ) IR > 50 Mohm

Main Excitor Armature Windings

R - Y 0.220 mohm Measured at -- Ve Wheel side

109

(- Ve WHEEL Towards Geneator )Y - B 0.222 mohm

B - R 0.226mohm

e) Exciter IR Values

A) Megger By 250 V Megger : Neutral To Shaft > 50 Mohm

B) Megger By 250 V Megger : + Ve Wheel To - Ve Wheel = 0 Mohm ( Rev.Bias)

C) Megger By 250 V Megger : + Ve Wheel To - Ve Wheel => 50 Mohm(Forward

Bias)

D) + Ve Wheel To Body > 50 Mohm

E) - Ve Wheel To Body > 50 Mohm

f) Quadrature coil

Quadrature Coil Res. Measurement IR Value

A) COIL 1 :Resi. By LR 205 Meter = 7.3 OHM (Temp = 320 C ) IR > 50 Mohm

B) COIL 2 :Resi. By LR 205 Meter = 7.3 OHM (Temp = 320 C ) IR > 50 Mohm

D) PMG (Pilot Exciter)

a) Pilot exciter resistance measured by LR-205 At Temp.= 32 0C

R-Y Res. B-Y Res. R-B Res. R-N Res. R-N Res. R-N Res.

5.68mOhm 5.70mOhm 5.69mOhm3.10mOhm 3.14mOhm 3.15mOhm

110

b) IR Value by 250 V hand operated megger > 50 Mohmc) Unit Aux Boards1. Unit Board A, B, C &D – Incomer and Tie I/C Breaker timing and contact resistance measurement.2. Unit Boards - A, B, C & D – Bus Transfer Scheme (BTS) trials

E) VALVES : 1. ACTUATOR VALVES - TURBINE SIDE

SNValve

no.Description

Connections removed

Cabling

& LS setting

Trials taken

1 FD 44 HPH 5A-6A Inlet valve

2 EX 31 TDBFP 6A Exhaust valve

3. EX 1 Extraction to HPH 6A

111

4. EX 2 Extraction to HPH 6B

5. EX 2A Extraction to HPH 6B

6. EX 3 Extraction common to HPH 6A & 6B

7. EX 4 Extraction to HPH 5A

8. EX 4A Extraction to HPH 5A

9. EX 5 Extraction to HPH 5B

10. EX 5A Extraction to HPH 5B

11. EX 6 Extraction to Deareator

12. AS 2 Aux. steam to Gland Steam Iso Valve

13. AS 4 Aux. steam to Deareator Main Iso

14. AS 12 Aux. steam to Deareator Bypass Iso

15. EX 34 Gland steam from CRH Iso valve

16. DR 4 HPH 6A Drip to HPH 5A Bypass Already removed

17. DR 11 HPH 6B Drip to HPH 5B Bypass

18. DR 19 HPH 5A Drip to Deareator Bypass

19. DR 27 HPH 5A Drip to Deareator Bypass

20. MS 502 HPCV 1 Strainer Drain




24. HR 502 IPCV 1 Strainer Drain




28. HR 113 LPBP Warm up Drain

29. HR 115

30. HR 108

31. Mal 11 HPCV1 to Turbine Line Drain



112


35. Mal 22 HP Turbine Casing Drain

36. MS-104

2. ACTUATOR VALVES - BOILER SIDE

SN Valve

no.Description Connections

removedCabling & LS setting

Trials taken

1) . MS201 Main Steam

2) MS203 Main Steam

2) S 37 Superheat Spray




6) B 55 Drum Vent

7) B 56 Drum Vent Motor NA

8) B 57 Drum Vent

9) B 58 Drum Vent

10) B 72 Drum Vent

11) B 73 Drum Vent

12) B 74 Drum Vent

13) B 75 Drum Vent

14) S 76 Start-up Vent




18) R 19 Reheat Spray




113

22) FD 50 Feed line Main

23) FD 50A Feed line Main

24) GD 1A Gas Damper

25) GD 1B Gas Damper

26) GD 3A Gas Damper Actuator

NA27) GD 3B Gas Damper Actuator

NA28) FD 40 Feed line Main

29) BS 4 EBD

30) BS 5 EBD

31) E 19 Economizer Inlet

32) FD 47 Full Load Line

33) GD41

34) GD4A1

35) GD4B2

36) GD 4B2

37) GD 6A1 ESP A-Pass inlet damper

38) GD 6A2 ESP A-Pass inlet damper

39) GD 6B1 ESP B-Pass inlet damper

40) GD 6B2 ESP B-Pass inlet damper

41) GD6C1 ESP C-Pass inlet damper

42) GD6C2 ESP C-Pass inlet damper

43) GD6D1 ESP D-Pass inlet damper

44) GD6D2 ESP D-Pass inlet damper

45) GD 7A ESP A-Pass outlet damper

46) GD 7B ESP B-Pass outlet damper

47) GD 7C ESP C-Pass outlet damper

48) GD 7D ESP D-Pass outlet damper

F) GTR R, Y, B :

114

1. GRP cubical panel 1-GT, Transformer Differential relay (87GT-1, 87GT-2) and Transformer

overall differential relay (87OA-1, 87OA-2) testing work carried out. Cubical panel 1G, Relay 50Z1

and 50Z2 testing work carried out.

2. GTR- Y phase, UAT-5A transformer testing work carried out.

3. GTR- R, Y and B oil pumps auto pick-up trials taken.

G) PLANT AUXILIARIES

1. GTR - R, Y, B Transformer testing and Buchholz protection Trial.

2. GTR - R, Y, B – HV Bushing Tan-delta and Capacitance measurement.

3. GTR R, Y and B,oil pumps ON/OFF and changeover trial.

4. UAT- A, B, C and D Transformer testing.

5. GTR - R, Y, B – Water flow switch servicing.

6. GTR and UAT – OTI and WTI calibration.

7. UAT- A, B, C and D Transformer Buchholz protection Trial.

8. GTR R, Y, B and UAT A to D, Buchholz local JB and RTD JB, polythene wrapping.

9. Generator Protection Panel Micom Relay testing.

10. Generator PT fuses replacement.

11. Generator Stator, Rotor, Main exciter, Pilot exciter – IR and Winding Resistance.

12. Exciter Diode Wheel diodes and Fuses checking.

13. Generator, GTR and UAT— protection/metering CT resistance measurement.

14. GCB ON/OFF and protection Trip Trial from PCR in co-ordination with 400KV GCR.

15. Unit Switchgear A, B, C and D – Incomer, Tie I/C and outgoing feeder Relay testing.

16. MDBFP-5C and D, Motor feeders relay testing.

17. Unit Board A, B, C &D – Incomer and Tie I/C Breaker timing and contact resistance measurement.

18. Unit Boards - A, B, C & D – Bus Transfer Scheme (BTS) trials.

19. LT Boards - EMPA,PA,ME Incomer feeder relay testing.

20. LT Boards - EMPA, PA control connection tightening.

21. PA Boardoutgoing feeders relay testing.

22. MA, MB, MC, MD, ME and MG Board I/c and Control supply panel indication lamp replacement.

23. DG set auto pick up trial.

24. Station Boards – SE11/1, SE11/2, SE12/1 and SE12/2 –normal I/C relay testing.

25. Station Transformer ST-3,HT side Protection Panel relay testing.

26. Station Transformer ST-3, R & B phase Lightening arrester checked found OK and Y phase

Lightening arrester replaced by 400 KV GCR.

27. Compressor Board - 5E Incomer and motor feeder relay testing work.

115

28. Generator Rotor Earth Fault (REF) protection, CarbonBrush holder assembly internal wiring checking.

29. UPS filter cleaning and Fan replacement.

30. Bottom Ash panel cleaning and connection tightening.

31. IAC/SAC Compressor control panel cleaning and TB tightening work.

32. AHP HT Board Relay testing.

33. 220 V Battery charger No.2, panel cleaning and condenser replacement.

34. 220 V Battery charger No.1 panel cleaning.

35. +/- 24V Battery charger G1 and G2 panel cleaning and condenser replacement.

36. PAH and SAH, Rotor stop indication L/S restoration.

37. Hot keys provided for DC Seal water pump A/B and EOP of TDBFP A/B.

38. ALL ESP fields OC test after clearance from BM-II and EM-II.

39. ID, FD, PA, CEP, BCW, MDBFP and C/M breaker protection trial.

40. Motorized valve L/S setting and trials after completion of BM (38) and TM (35) work.

41. CCW pump house,CW(11 KV) and CWS(3.3KV) Board Incomersand outgoing feeders relay testing.

42. ACW, CCW control panelcleaning and connection tightening.

43. CCW BFV local panel connection tightening and local JB polythene wrapping.

44. CTPA Board relay testing and connection tightening.

45. CWX-A &B Transformer, OTI/WTI calibration.

46. 5CWXA/XB/XC and 5CTXA/XB, transformer Buchholz’s alarm and trip protection trials.

47. CCW-A, CCW-C and CCW-D control panel annunciator replacement.

48. ACW and CCW pumps breaker protection trial.

49. Major modifications carried out

50. 100% Stator E/F protection, 40MW interlock introduced in MICOM 343 relay as approved by

competent authority.

51. Hot keys provision at PCR for EOP of TDBFP A/B and DC seal water pump A/B.

52. Following relays found faulty, same replaced with spare relays.

SE11/1, Incomer Y phaseOver current relay (CDG63).

PA Fan 5A, Motor protection relay (SPAM150)

5DBoard, TIE to CCW, E/F Relay (IBX164)

RWP- NDM pump B, Motor protection relay(CTMM)

53. Works carried out from 400 KV GCR side,

54. The Measurement of Tan delta & capacitance of R-phase synchronizing PT is done.

55. The IR of R, Y & B-phase L.A.'s of GT-5 is carried out. During, taking IR, the IR value of B-phase L.A.

of GT-5 is found low and hence, the B-phase L.A. is replaced by new ALSTOM make L.A.

56. Maintenance of CB & PG isolators is carried out.

116

57. The 01 no. disc insulator string of R-phase in gantry near to canteen is replaced.

58. Generator Dynamic testing completed at 0055 Hrs on 30.01.2016 and unit synchronized at 02.06.Hrs

on 30.01.2016.

U # 5 GENERATOR SCC : Date of test :- 29/01/2016

SR. NO. GEN. AMP

QUADRATURE. COIL

VOLT( CJN04

PANEL ) TB- LA005- 101 &

102

MANUAL

POT. POSN( CJN0

4 PANEL

)

AUX. EXC.VOLT( - L TO +

L)( CJN

01 PANE

L )

AUX. EXC. FIELD AMP. (mV ACROSS

SHUNT)( CJN01 PANEL

)CA003(m)

(150A/60 mv)CA004(a)

(150A/60 mv)

UST (DQ069-

H2)( CJN04 PANEL

)

GENERATOR PT VOLTAGE FIELD AMP

PT ICJJ09-

X01-RY/YB/B

RVolts

PT IICJJ09-

X01-RY/YB/B

RVolts

PT III CJJ09-

X01-RY/YB/B

RVolts

COD 8

METER

Previous 2100 A 2.75 V 0.854.56

V2.65mV/2.4mV (-)448

mV1.81 V (avg)

1.79 V (avg)

1.79 V (avg) 200 A

1 1997 A 3.60 V 0.85.13

V2.71 Mv/2.73mV (-)425

mV1.72V (avg)

1.69 (avg)

1.70 (avg) 180 A

Previous 9900 A 16.22 V 3.77 23.46 V 14.5mV/14.4mV (-)765

mV8.48 V (avg)

8.45 V (avg)

8.44 V (avg)

1600 A

2 10110 A 16.34 V 3.8 22.32

V15.13 mV/15.20

mV(-)746

mV8.62 (avg)

8.58 V (avg)

8.60 V (avg)

1400 A

U # 5 GENERATOR OCC :

SR. NO. GEN. VOLT

QUADRATURE. COIL VOLT

( CJN04 PANEL ) TB- LA005- 101 &

102

MANUAL POT. POSN

( CJN04 PANEL )

AUX. EXC.VOLT

DC( - L TO

+ L)( CJN01 PANEL

)

AUX. EXC. FIELD AMP.

(mV ACROSS SHUNT)( CJN01 PANEL )

CA003(m) (150A/60mv)

CA004(a) (150A/60 mv)

UST DC Volts

(DQ069-H2)MAN( CJN04 PANEL )DC091-S2(A)

AVR PT VOLT ( CJN-04 )

FIELD AMP

COD 8 METER

RYLA010-251A-252A

& WA-511-512

YBLA010-252A-253A

& WA-512-513

BRLA010-253A-251A

& WA-513-511

Previous 19.5 KV 11.42 V 2.55 16.17 9.1mV/9.2mV (-)635mV/

95.1/94.9 V

95.2/95.2 V

95.2/95.2 V 0

117

(-)1.01 V

1 21.1 KV 13.08 V 2.98 18.71 11.14 mV/10.91 mV

(-)660mV/ 105.06 / 105.37 / 105.38 / 0

(-)9.2 V(pot 4.5) 105.28 V 105.31 V 105.35 V

GENERATOR DYNAMIC TEST :Date of test :29/01/2016

* GENERATOR SHORT CKT TESTGENERATOR PROTECTION RELAY GPR-1 & 2 ( P-343 )

Sr. No

RELAY CT NO. & CTR

NEW TB NO.

MEASURED CURRENT READINGPrevious( 210

0 A)Previous( 9900

A )Current (2008A)

Current (10080A )

Measure-1

GPR-1 (Pri.)

GPR-2 (Sec.)

GPR-1 (Pri.)

GPR-2 (Sec.)

GPR-1 (Pri.)

GPR-2 (Sec.)

GPR-1 (Pri.)

GPR-2 (Sec.)

1 GPR 1&2, P-343,

87G AND OTHER

PROTECTION (GEN.

DIFF.)

CT D1 20000/5

A NEU.SIDE BIAS-1

1G,TB-1-15 IA-1

2105 A 526 mA 9881 A 2.47 A

1990 A

0.497 A 10000 2.52 A

13 IB-12101

A 524 mA 9887 A 2.47 A1986

A0.498

A 10000 2.53 A

11 IC-12112

A 526 mA 9927 A 2.48 A1994

A0.498

A 10000 2.53 ANeutral-

9Measur

e-3

CT D2 20000/5

A HV SIDE

BIAS-2

1G,TB-1-1 IA-2

2111 A 527 mA 9886 A 2.47 A

1970 A

0.495 A 10000 2.52 A

3 IB-22105

A 526 mA 9865 A 2.47 A1978

A0.495

A 10000 2.51 A

5 IC-22099

A 528 mA 9926 A 2.47A1991

A0.497

A 10000 2.51 ANeutral-

7Measur

e-3

SPILL

I(A) Diff. 0 mA 0 mA 0 mA 0 mA 0 0 0 0I(B) Diff. 0 mA 0 mA 0 mA 0 mA 0 0 0 0

I(C) Diff. 0 mA 0 mA91.50

A 18 mA 0 0 0 0.017Measur

e-3I(A) Bias 2104

A526 mA 9883 A 2.47 A 1974

A0.497

A10000 2.52 A

118

I(B) Bias 2099 A 525 mA 9877 A 2.47 A

1971 A

0.496 A 10000 2.52 A

I(C) Bias 2115 A 529 mA 9930 A 2.48 A

1978 A

0.498 A 10000 2.52 A

Measure-1

CT P 200/1 A

1G,TB-1-18

IN Measure Magnitu

de

0.0 A 0.0 A 0.0 A 0.0 A 0 0 0 0

19NGT(95

%) 18K/24

0V

1G-TB1-48

VN Measure Magnitu

de

0 V 663 mV 3.2 V 0.0 V 0 0 0 0

49Measur

e-3100% S-

E/FVN 3rd Hrm. 49 V

652.2 mV

237.9 V

3.171 V

46.84 V

621.7 V 254

3.229 V

GEN. TRANSFORMER RELAY 87GT-1 and 87GT-2 ( P-642 )

Sr. No

RELAY CT NO. & CTR

NEW TB NO.

Previous ( 2100 A )

Previous( 9900 A )

Current (2010 A)

Current ( 10000A )

Measure-1

87GT-1 (Pri.)

87GT-2 (Sec.)

87GT-1 (Pri.)

87GT-2 (Sec.)

87GT-1 (Pri.)

87GT-2 (Sec.)

87GT-1 (Pri.)

87GT-2 (Sec.)

2

87GT 1&2,

P-642, AND

OTHER PROTECTI

ON ( TRANS.

DIFF. )

BCT-2 1000/

5 A HV

SIDE BIAS-1

1GT-TB1-45 IA-1 107 A 535 mA 508 A 2.54 A

101.1 A

0.506 A

0.519 A 2.59 A

47 IB-1 105 A 530 mA 505 A 2.52 A100.3

A0.505

A0.518

A 2.58 A

49 IC-1 107 A 533 mA 507 A 2.53 A100.8

A0.502

A0.518

A 2.58 ANeutral-

51

Measur

e-1

BCT-6+7

12000/5 A LV

SIDE BIAS-2

1GT-TB1-57 IA-2 2100 A 875 mA 9913 A 4.13 A 1982 A

0.827 A

10140 A 4.22 A

59 IB-2 2100 A 872 mA 9897 A 4.12 A 1977 A0.828

A10120

A 4.21 A

61 IC-2 2130 A 879 mA 9965 A 4.15 A 1993 A0.840

A10180

A 4.23 ANeutral-

63

Measur

e-2 SPILL I(A) 0.003 0.004 0.016 0.016 0.004 0.004 0.017 0.017

119

Diff. PU PU PU PU PU PU PU PU

I(B) Diff.

0.004 PU

0.004 mA

0.016 PU

0.016 PU

0.004 PU

0.004 PU

0.017 PU

0.017 PU

I(C) Diff.

0.004 PU

0.004 mA

0.016 PU

0.016 PU

0.004 PU

0.004 PU

0.017 PU

0.016 PU

Measur

e-2

I(A) Bias

0.125 PU

0.125 PU

0.594 PU

0.593 PU

0.119 PU

0.120 PU

0.607 PU

0.607 PU

I(B) Bias

0.125 PU

0.125 PU

0.593 PU

0.594 PU

0.119 PU

0.119 PU

0.604 PU

0.602 PU

I(C) Bias

0.125 PU

0.125 PU

0.594 PU

0.594 PU

0.119 PU

0.119 PU

0.607 PU

0.606 PU

GT HV SIDE S/B BACKUP E/F(51 NGT)

Measur

e-1 BCT-4 1000/

1 A

1GT-TB1-53

IN-HV Measd Mag.

0 03.124

A 0.0 A2.163

A 0 0 055

GENERATOR AND TRANSFORMER PROTECTION 870A-1 & 2 ( P-645 )

Sr. No

RELAY CT NO. & CTR

NEW TB NO.

Previous(2100 A)Previous(990

0 A)Current(2010

A)Current(1001

0A)

Measure-1 87OA-1

(Pri)

87OA-2 (Sec) 87OA-

1 (Pri)

87OA-2

(Sec)87OA-1 (Pri)

87OA-2

(Sec)87OA-1 (Pri)

87OA-2

(Sec)3 87 OA 1

& 2 P645 CT

CORE-1 1GT-

TB1-1IA-1 106 A 107 mA 509 A 508

mA100 A 0.101

A520.8

A0.518

A

120

AND OTHER

PROTECTION

1000/1 A HV SIDE BIAS-1

3 IB-1 106 A 107 mA 506 A507 mA 98 A

0.103 A

518.5 A

0.514 A

5 IC-1 106 A 106 mA 508 A507 mA 100 A

0.102 A

520.4 A

0.520 A

Neutral-7

Measu

re-1

CT A 20000/5 A GEN.(N)SIDE BIAS-2

1GT-TB1-9 IA-2 2100 A 521 mA

9920 A 2.48 A

1988 A

0.496 A

10130 A

2.526 A

11 IB-2 2100 A 521 mA9900

A 2.43 A1979

A0.497

A10110

A2.523

A

13 IC-2 2100 A 520 mA9970

A 2.49 A2009

A0.502

A10170

A2.543

ANeutral-

15

Measu

re-3

SPILL

I(A) Diff.

0.003 mA

0.002 mA

0.015 mA

0.014 mA

0.004 mA

0.003 mA

0.019 mA

0.016 mA

I(B) Diff.

0.003 mA

0.002 mA

0.015 mA

0.015 mA

0.003 mA

0.004 mA

0.016 mA

0.015 mA

I(C) Diff.

0.003 mA

0.004 mA

0.016 mA

0.015 mA

0.003 mA

0.003 mA

0.014 mA

0.015 mA

Measu

re-3

I(A) Bias 0.125 A 0.125 A

0.595 A

0.595 A

0.120 A

0.118 A

0.607 A

0.607 A

I(B) Bias 0.125 A 0.125 A

0.594 A

0.594 A

0.119 A

0.118 A

0.606 A

0.606 A

I(C) Bias 0.125 A 0.126 A

0.595 A

0.595 A

0.119 A

0.118 A

0.607 A

0.605 A

GTR REF 64GT

Measure-1

BCT 3+5 R ph

1000/1A

1GT, TB1-33

IN-TV(R

Ø) 0 0 0 0 35

Spill Across Stab. Res. ( 1GT-Panel )

SRR - 122 mV/ 0.42 mA

SDR - 122 mV

SRR - 132.6 mV

SDR - 132.8 mV

BCT 3+5 Y ph

1000/1A

1GT,TB1-37

IN-LV(Y

Ø) 0 0 0 0 0 0 0 039


SRY - 322 mV/ 1.46 mA

SDY - 322 mV

SRY - 337.8 mV

SDY - 313.01 mV

BCT 3+5 B ph

1000/1A

1GT,TB1-41

IN-HV(B

Ø) 0 0 0 0 0 0 0 043

121


SRB - 157 mV/ 0.255 mA

SDB - 156 mV

SRB - 157.33 mV

SDB - 156.8 mV

GENERATOR LBB PROTECTION RELAY 50Z1 & Z2 (P-141)

Sr. No

RELAY CT NO. & CTR

NEW TB NO.

Previous(2100 A)

Previous(9900 A)

Current(2000 A)

Current( 10000 A)

Measure-1

50Z-1 (Pri)

50Z-2 (Sec)

50Z-1 (Pri)

50Z-2 (Sec)

50Z-1 (Pri)

50Z-2 (Sec)

50Z-1 (Pri)

50Z-2 (Sec)

4

50Z1&Z2 LBB

PROT. P141

CORE 4 1000/1

A

1G, TB1-21 IA-1

106.5 A

106.8 mA

503.8 A

504.2 mA 101 A

0.101 A 516.1 A 0.514 A

23 IB-1106.9

A105.6

mA502.8

A502.2

mA 99.9 A0.102

A 512.8 A 0.512 A

25 IC-1105.5

A106.9

mA505.0

A504.1

mA100.7

A0.100

A 515.6 A 0.513 ANeutral-27

CJJ-09 PANEL MEASURED CURRENT READING

2100 A 9900 A (1997 A) (10000 A)

Previous Previous Current Current

5 Metering CT

CT F 20000/5A

CJJ09-X02-1 499.2 mA 2.35 A 0.460 A 2.40 A5 500.2 mA 2.37 A 0.473 A 2.46 A7 504.5 mA 2.39 A 0.454 A 2.39 A

6 EHG+AVR CT

CT G 20000/5A


7 EHG CT CT H 20000/5A


DURING OC TEST

MEASUREMENT-1 UAT-A UAT-B UAT-C UAT-D

VAB / IA - 1 12.23 mA 12.51 mA 10.01 mA 11.36 mA

VBC / IB - 1 13.80 mA 13.33 mA 10.03 mA 10.70 mA

VCA / IC - 1 18.07 mA 17.58 mA 11.74 mA 12.30 mA

122

U # 5 GENERATOR SCC ( READINGS OF COD 8 )

SR.NO

.

CT NO.&

CTR

LOCATION TB NO.

CT CURRENT for

2100 A / 9900A

CT CURRENT for

2012 A /10100 A

GEN. CURRENT ON COD8/TRIVECTOR Previous

Current

Previous Current

2100 A 2012 A 9900 A 10010 A

1

METERING CT

CT ' F '20000/5

COD 8

1T - 82 (R) 484 mA/2.33 A 460 mA/2.40

A 2103A 2007 A 9890A 10010 A

1T - 83 (Y) 500 mA/2.37 A 473 mA/2.46

A 2102A 2011 A 9897A 10003 A

1T - 84 (B) 502 mA/2.38 A 454 mA/2.39

A 2105A 2012 A 9905A 10010 A

U # 5 GENERATOR OCC ( READINGS OF COD 8 )

SR.NO. PT III LOCATIO

N TB NO. PT VOLTAGE AT 19.5KV

PT VOLTAGE AT 21.1KV

GENERATOR KV ON COD8

RY YB BR

1 METERING PT COD 8

1T - 91 & 92 ( RY ) 94.9 V 105 V

19.5 KV (Previous)

19.5 KV (Previous)

19.5 KV (Previous)1T - 91 & 93

( BR ) 95.2V 105.2 V

1T - 92 & 93 ( YB ) 95.3V 105.3 V

21.32 (current)

21.05 (current)

20.91 (current)2 GEN. SYN.

PT COD 8 3T - 105 & 106 54.4 V 65.3 V

PART- III1. LIGHT UP, ROLLING AND SYNCHRONIZATION OF UNIT: A) BOILER HYDRAULIC TEST:

123

1. DepartmentaL : Date : 24/01/2016 at 17:58Hrs Boiler press : 250Kg/CM2. And drum depressurised at

18:26 Hrs.

2. In presence boiler inspector : Date ; 26/01/2016 at 14.38Hrs., Boiler press ; 250Kg/CM2 kept for 3

minute and that pressure reduced to 50 kg/cm2 at 15:00 hrs. and boiler hydraulic test done at 15:45

hrs.

B) REHEAT HYDRAULIC TEST: Date – 24/01/2016 at 19:00Hrs. Press – 50Kg/cm2

C) OTHER ACTIVITIES :

Generator Filling:

CO2 filling

Starting Date &Time : 27/01/16 at 23.31hrs

Cylinder consumed : 70Nos with purity 100%.

Filling done : 28/01/16 at 14.25hrs

H2 filling activity carried out.

Starting Date &Time : 28/01/16 at 15.00 Hrs

Cylinder consumed : 171+52=123Nos. (pressure-3.25 kg/cm2)

Filling done : 29/01/16 at 11.45hrs

First Boiler Light up on 29/01/16 at 06.45hrs, Second Boiler Light up on 21/07/15 at 00.42hrs,

First blow down given at 10kg/cm2 at11:42hrs., second blow down given at 20kg/cm2 at 12:50 hrs

and third blow down given at 30kg/cm2 at15:19 hrs.,

Fourth blow down given at 40kg/cm2 (i) 16:21hrs

Fifth blow down given at 40kg/cm2 (ii) 16:47hrs

Sixth blow down given at 40kg/cm2 (iii) 17:46hrs

At 14:04 vacuum pump-A and at 14:15 vacuum pump –B started

Stop valve opened at 18:40, turbine rolled to 3000 rpm at 21:42 hrs.

Set synchronized on 30/02/16 at 02.07 hrs.

3. POST OVERHAUL ACHIEVEMENTS : PERFORMANCE OF UNIT- V BEFORE AND AFTER

124

Sr. No.

Parameters Design Values

Before OH

After

OH

13-Dec-15

24-Feb-16

A Turbine Side Performance

1 Load (MW) 500 423 424

2 Main Steam Flow 1524 1298

3 Steam Flow / MW (T/MW) 3.05 3.06

4 Main steam Temp (Deg C) 537 530 540

5 HRH steam Temp (Deg C) 537 535 532

6 HP Cylinder Efficiency (%) 85.96

7 IP Cylinder Efficiency (%) 91.41

9 Gross Unit Efficiency (%) 38.37

10 Vacuum (mm of Hg) 670.60 8753 8843

11 CW Temp I/L (Deg C) 30.00 30.4 33

12 CW Temp O/L (Deg C) 40.20 42.0 44.2

13 Air ingress kg/hr 40.00 64 64

14 Cleanliness Factor 89.00 56 61

15 Gross Turbine Efficiency (%) 43.61 39 44

B Boiler Side Performance

1 Gas inlet temp (PAH A/B) º C 356 339/317 331/334

2 Gas Outlet temp (PAH A/B) º C 136 101/96 97/112

3 Gas inlet temp (SAH A/B) º C 356 372/371 353/352

4 Gas Outlet temp (SAH A/B) º C 136 199/176 135/151

6 Pri.Air temp after (PAH A/B) º C 332 235/207 265/254

7 Sec.Air temp after (SAH A/B) º C 326 313/312 330/332

8 Pri. Air / Sec Air I/L Temp º C 42/43 39/41

9 Gas side effy (PAH A/B) % 67 74/76 70/70

10 Air side effy (PAH A/B) % 92 69/65 76/75

11 Gas side effy(SAH A/B) % 67 54/52 70/55

12 Air side effy (SAH A/B) % 92 79/84 85/90

125

13 Seal leakage (PAH A/B) % 15.56 23 10

14 Seal leakage (SAH A/B) % 6.10 23 8

15 Total Air Flow (T/hr) 1853 1476 1813

16 Total Coal Flow (T/hr) 300 341 330

17 Excess air % 20 11 16

18 Economizer inlet temp º C 253 204 241

19 SH Spray T/hr 0 157 131

20 RH Spray T/hr 0 62 15

C Performance Indicators

1 Boiler Efficiency 88.1 81.1 83.9

2 Corrected Boiler Efficiency 88.1 85.6 87.1

3 Gross Turbine Heat rate 1972 2170 2016

4 GCV of Coal 3750 3168

5 Gross Unit Heat rate 2241

6Sp Coal Consumption (As per Heat rate)

0.598 0.804 0.77

Last Overhaul: 14-07-13 to 31-08-13 (AOH)

Current Overhaul Started from: 27-12-2015 (18:50 hrs) to 30-01-2016 (02:07 Hrs) (33 Days)

Following Major Works are being carried out :• Complete Air Heater Basket assembly is replaced.

• Total 32 coal compartment assemblies replacement with Upgraded coal compartment assemblies.

• TDBFP-5B Cartridge replacement & Overhaul.

• ACW & CCW header separated.

• IDCT new cell interconnection with CCW return line of tower 5A & 5B is completed successfully during

COH.

Unit-5 (COH) – Surprises : • LPT 2R blade no. 35 found damaged

• HPCV no. 3 cone found damaged.

• HP Bypass 1 & 2 Seat found Damaged.

• IPT B/H casing inlet 1st stage stationary blades one bolt observed entangled in blade.

• Pitting marks observed on Gen Rotor exciter end face.

126

• Compressor stationary blades 1st row observed denting marks.

• Leakage observed in 2 nos Current Carrying bolts. Generator rotor & Exciter rotor 1 no. each

Works Carried out :1. Resolving ESV 1 To 4 Opening Problem

• ESV 1 to 4 pilot Valve found jam, 3 Nos. of ESV valves pilot opened & made free after servicing, One

No ESV found jam to open so replaced by new.

2. Resolving Turbine Speeding Problem

• HPCV 3 seat Damage – Seat Repaired & IPSV Seat damage repaired by machining.

3. Resolving Factors Responsible For Poor Vacuum

• LPT inlet bellow found puncture – Replaced with new

• Condenser tubes found chocked/blocked - Tube cleaning by Hydro jetting & Bullet shot

4. Resolving Factors Responsible For Poor Vacuum

• Both TDBFP diaphragm found raptured replaced with new

• Both TDBFP Exhaust butterfly valve found damaged so sealing ring replaced.

• Vacuum pump 5A/5B diaphragm observed rupture, replaced with new.

5. Resolving EHC hunting problem

• Cleaning and servicing of EH amplifier block

6. Condenser Cathodic Protection –

• 80 nos. of Condenser cathodic protection elements installed in Waterbox to avoid (Hydrogen

embrittlement) deposition of hard scales in condenser & Improving condenser performance and

reduction in fouling factor

7. GTR Cooler Cleaning By SILICO6 –

• GTR coolers observed fully chocked up causing high temperature problem. Lot of Ash deposition

observed in tubes from ACW sump. Cleaned by new technique organic compound SILICO6.

8. New soot blowing line from PRDS station to A/H is provided for effective air heater soot blowing.

(previously soot blowing was done through service air)

127

9. 100% Stator earth fault protection which was initially bypassed during synchronization, since last two

and half years is now put in service after trial. Now 40 MW interlock introduced.

PERFORMANCE • Condenser Side

Date Design 03/12/2015 05/02/2016

Load (MW) 500 420 459

Vacuum -670 631 652

C.W Inlet temp 30 32.67 30.55

C.W Outlet temp

(mean)40.2 43.89 41.97

LPT Exhaust Temp 43 51.37 47.84

Condensate Temp 43.1 50.36 46.27

Actual TTD 2.9 8.62 5.82

Condenser

Efficiency77.86 56.6 66.2

Cleanliness Factor 89.29 56 61

• Air Heater Side

Air heater performance Design 03/12/2015 05/02/2016

128

L R L R

a) O2 at AH inlet (%) 3.5 3.4 3.6 5.0 5.2

b) O2 at AH outlet (%) 6.0 6.7 6.8 6.2 6.6

d) Flue gas temp at PAH I/L (Oc) 356 340 312 331 334

e) Flue gas temp at SAH I/L (Oc) 356 373 354 376 354

f) Flue gas temp at AH Comn O/L (Oc)

136 173 154 134 154

g) PA temp at AH outlet (Oc) 332 246 216 261 261

h) SA temp at AH outlet (Oc) 326 303 305 326 322

i) Gas side effy (%) (PAH / SAH)

67 74.8/54.7 76.2/52.8 69.9/70.1 70.2/54.2

j) Air side effy (%) (PAH / SAH) 92 69.2/79.3 65.3/84.6 76.4/85.3 75.6/90

k) Air inleakage (%) --- 23 23 8 10

Excess Air (%) 20 11 16

• Boiler Side

129

Date Design 03/12/2015 05/02/2016

Load (MW) 500 420 459

Operating boiler Effy. (%) 88.1 81.05 83.96

a) Unburnt loss (%) 0.60 0.30 0.33

b) Dry flue gas loss (%) 4.64 9.85 7.48

c) Coal (Moisture+H2) loss (%) 5.61 7.46 7.03

d) GCV of COAL 3750 3215 3416

Corrected blr effy (Design coal) 88.1 85.58 86.74

• Turbine Side

Date Design 03/12/2015 05/02/2016

MS flow at HPT inlet-T/Hr 1524.3 1326 1310

MS temp at HPT inlet-Deg C 537 534.73 536.96

MS press. at HPT inlet-kg/cm2 170 141.64 140.92

HRH temp at IPT inlet Deg C 537 528.00 526.70

HRH press. at IPT inlet-kg/cm2 39.4 33.65 36.99

HPT exhaust steam temp Deg C 342.6 350.91 346.95

130

CRH pressure-kg/cm2 43.90 39.69 40.03

Gross Turbine Heat Rate 1972 2170 2016

Gross Turbine Efficiency 43.61 39.63 44.09

• HR Deviations

Date 03/12/2015 05/02/2016 Saving (Rs/Day)

Deviation in GUHR (Controllable)

Loss due to un burnt carbon -9.73 -7.40

Loss due to dry flue gas 183.83 81.25 6,45,337

Radiation & other losses -7.20 -10.02

MS temp at HPT inlet 0.78 0.10

MS pressure at HPT inlet 26.99 27.65

Re heater pressure drop 7.97 -4.10

Condenser vacuum 52.55 22.92 1,90,768

Loss due to Partial Loading 43.87 15.65

FW Temp at Eco Inlet 6.01 6.01

SH Spray 4.27 4.60

Deviation in GUHR (Un-Controllable)

Loss due to moisture in fuel 46.05 46.88

Loss due to H2 in fuel 16.18 -6.48

HRH temp 4.54 4.58

RH Spray 14.75 4.90 65,010

POG Observations1. Improvement in ID/PA Current by @15 & 10 Amp Respectively.

131

Auxiliary Unit Before After Reduction in Current

ID Fan-A Amp 122 105 14

ID Fan-B Amp 123 95 23

ID Fan-C Amp 122 105 14

ID Fan-D Amp 120 110 8

PA Fan-A Amp 145 125 14

PA Fan-B Amp 139 130 6

2. Increase in ID margin by 30% from 82% at 373 MW load to 52% at 443 MW load.

Auxiliary Before AfterGain in Vane

Position

ID Fan-A 81.6% 52.1% 29%

ID Fan-B 82.1% 52.5% 30%

ID Fan-C 81.7% 52.2% 30%

ID Fan-D 82.0% 52.4% 30%

IMPREOVEMENTS

132

1. Condenser Vacuum improved by @ 21 mmHg

2. Condenser cleanliness factor improved by @ 5 %

3. Improvement in Air side efficiency of Air heater observed.

4. Reduction in air in leakages @ 14 %

5. Reduction in RH spray by @ 52 T/hr resp.

6. Boiler efficiency improved by 2%

7. Improvement in Gross turbine heat rate by @154 Kcal/Kwh

8. Now after COH no boiler side drain valves are passing as per last test.

9. Windbox DP improved by @25 mmwcl i.e from 75 / 80 to 105 / 100

133

Unit-5 COH-2015 EXPENDITURE (In lakhs)

Unit-5 COH-2015-16 Expenditures (In Lakhs)

Section R & M Expenditures Total(R & M

Expenditures)

Capex Expenditures Total(Capital

Expenditures)

Supply Works Supply Works

BM-II 1322.977 669.231 1992.209 540.898 52.582 593.481

TM-II 284.303 388.395 672.698 NIL NIL NIL

EM-II 52.75 50.63 103.38 NIL NIL NIL

I & C-II 14.46 21.72 36.18 NIL NIL NIL

Test-II 5.47112 7.97110 13.44222 NIL NIL NIL

ODP-II 119.58 46.51 166.09 NIL NIL NIL

Total 1799.54112 1184.4571 2983.99922 540.898 52.582 593.481

Grand Total (Rs. in Lakhs) 3577.48022

134

DETAIL COSTING OF EACH SECTION AS FOLLOWS:

Expenditures of Boiler Maintenance-II during COH-U5 in 2015-16R & M EXPENDITURE

Sr. No.

Works carried out Name of Contractor

Supply Cost

Works Cost

Total Cost

1 Work of repairs of HP parts in Furnace

Zone ( I Pass)

M/S. Sunil Hi-

Tech

2665330 6810350 9475680

2 Work of repairs of HP parts in Furnace

Zone ( I Pass)

M/S. Adore

Contractors

1777155 6817666 8594821

3 Work of repairs of HP parts repairs in

LTSH & Eco.(II Pass)

M/S. Bhavana

Const. Co.

727685 2615503 3343188

4 Work of repairs of HP parts repairs in

LTSH & Eco.(II Pass)

M/S. V. K.

Enterprises

698920 2615503 3314423

5 Work of Repairs of Air Pre-heaters (PAH

& SAH) RHS

M/S. Bhavana

Const. Co.

42448061 2138610 44586671

6 Work of Repairs of Air Pre-heaters (PAH

& SAH) LHS

M/S. Sunil Hi-

Tech

1710888 1710888

7 Servicing of BT Mechanism (Corner 1 &

2)

M/S. Bhavana

Const. Co.

12051737 788930 12840667

8 Servicing of BT Mechanism (Corner 3 &

4)

M/S. Adore

Contractors

631144 631144

9 Servicing of FG & Air Dampers of PAH &

SAH

M/S. Ganesh

Engg.

289350 469232 758582

10 Servicing of ID, FD, PA Fans M/S. Ganesh

Engg.

170550 467858 638408

11 In-Situ repairs of Control and HP Isolating

valves.

M/S. Ideal

Engineering

6875865 1663489 8539354

12 Work of Radiographic Inspection of weld

joints.

M/S. Parikshak

Nirikshak

0 111015 111015

135

13 Work of Ultrasonic Thickness

Measurement of Boiler Tubes

M/S. P R

Sahare

0 1891444 1891444

14 Carrying out CAVT & Implementation of

Erosion Control Device

M/S. Favourite

Fabricators

5756006 1078656 6834662

15 Inspection & Scanning of WW Tubes by

LFET

M/S. MRP Nair

Engineers

0 2724730 2724730

16 Complete RLA Study of Boiler M/S. BHEL 0 8696894 8696894

17 Providing Assistance to BHEL Team for

RLA Study

M/S. Ganesh

Engg.

0 320816 320816

18 Work of Replacement of BCWP motor &

its cooler cleaning

M/S. V.A.

Constructions

95000 170328 265328

19 Work of Replacement of SAH FG Outlet

damper GD 4A

M/S. Bhavana

Const. Co.

4614645 574164 5188809

20 Servicing of Actuators M/S. S. K. Sales

Corp.

65000 330550 395550

TOTAL Rs. र 78,235,30

4

र 42,627,77

0

र 120,863,074

COAL MILLS

S.No Particular Supply Cost Work Cost Consumables

1 All Coal Feeder Iso Gates Servicing 138400 49595 4,655,550

2 All Coal Feeder COC Modifications 246400 25000

3 All HAG/HAD Servicing 0 24812

4 All CAG/CAD Servicing 0 18609

5 CAD Hastalloy Seal replacement 2040000 552400

6 C/M 5A Airport replacement 400000 80000

7 C/M 5E 'C' Type 3471682 300000

136

8 Coal Pipe/Bends/Orifice Repl 12554266.96 4531156

9 Classifier Vanes Servicing 0 93903

10 Seal Air Fan Suction Filter Cleaning 0 46028

11 Painting of Coal Mills & Structures

12 Repair/Replacement of Drive Air Seal

System, MDV, MOE

2687304 1294541

र 21,538,053 र 7,016,044 र 4,655,550

र 33,209,647

ESP

S.NO DESCRIPTION OF WOK COSTING SUPPLY

COSTING WORKS

TOTAL

1 REPAIRS OF FLUE GAS DUCT FROM

ECO O/L TO ESP I/L, HOT AIR DUCT

AND ESP O/L DUCT

3760500 2173954 5934454

2 SERVICING OF BOTTOM ASH

EVACUATION SYSTEM INTERNAS AND

REPLACEMENT OF DAMAGED

REFRACTORY

2558246 3130324 5688570

3 WORK OF SERVISING OF COARSE

ASH EVACUATION SYSTEM AND

REMOVAL OF ASH & DEBRIES.

1554000 407000 1961000

4 WORK OF SERVISING OF FLY ASH

EVACUATION SYSTEM.

1475000 365000 1840000

5 WORK OF SERVISING AND

OVERHAULING OF COMPLETE ESP.

5150000 1791098 6941098

6 WORK OF SERVISING OF GUILLITINE

GATES OF ESP I/L & O/L.

200000 904616 1104616

137

7 WOKRK OF REPLACEMENT OF

METALLIC EXPANTION JOINTS

4516352 1204616 5720968

8 WORK OF SERVISING OF ASH FEED

GATE.

850150 355000 1205150

9 WOKRK OF REPLACEMENT OF FABRIC

EXPANTION JOINTS

2859350 1523184 4382534

10 WORK OF CFD ANALYSIS &

INSTALATION OF DIVERTER PLATES

4945250 5472400 10417650

र 27,868,848 र 17,327,192 र 45,196,040

TOTAL R & M COST

र 199,268,761

CAPITAL EXPENDITUREPRESSURE PARTS

S.No. ITEMS Supply Cost Works Cost Total Cost

1 BASKETS 38943998 1710888 40654886

1710888 1710888

2 CCA 10531200 631144 11162344

631144 631144

3 FG DAMPER 4614645 574164 5188809

54089843 5258228

Capital Exp. Total र 59,348,071

COAL MILL

S.No.

ITEMS Supply Cost Works Cost Total Cost

1 NIL 0 0 0

138

ESP

S.No.

ITEMS Supply Cost Works Cost Total Cost

1 NIL 0 0 0

TOTAL SUPPLY COST 78235304

TOTAL WORKS COST 42627770

TOTAL COST 120863074

Less Capex Cost 59348071

Total R&M Cost (Total Cost - Capex) र 61,515,003

Consumables R&M CAPEX

Supply Works Supply Works

PP र 4,655,550 र 78,235,304 र 42,627,770 र 54,089,843 र 5,258,228

CM र 21,538,053 र 7,016,044 र 0 र 0

ESP र 27,868,848 र 17,327,192 र 0 र 0

Total र 4,655,550 र 127,642,205 र 66,971,006 र 54,089,843 र 5,258,228

र 132,297,755

GRAND

TOTAL

र

258,616,832

139

TURBINE MAINTENANCE - II

SR. NO

E-CODE MATERIAL DESCRIPTION UNIT QTY AMOUNT

1 A115050250050004 PMP OIL TUSHACO T3SA38/36 PMP CTDG ASSY EA 1 2,112,078.21

2 A036020220010003 FIRE RESISTANT FLUID REOLUBE TURBOFLUID KG 690 1,995,273.00

3 A093240010050013 TBN STEAM MODULE CASING COMPENSATOR DN

60

EA 1 1,500,000.00

4 VALVE CONE FOR HPCV NO 3 EA 1 1,200,000.00

5 A133190010010025 DRG 09-SHF2 / 162-E5 COMPLETE MECH SEAL EA 1 1,175,697.29

6 A031020010010001 HEATEXCH CRFLOW CONDNSR TUBE EA 154 956,878.69

7 A133190010020001 M/SEAL BFP NDE COMPLT MECH SEAL EA 1 944,763.38

8 A093590010010009 TBN LPT BLADE MOVING MOVING BLADE 2L EA 2 886,206.90

9 A115090380050142 PMP WTR WEIR THRUST BRG EA 2 742,320.00

10 A093590010010013 MVNG BLADE CLAMPING PIECE P.N.007 EA 504 737,409.32

11 A093290040010021 PILOT VALVE DRG.NO. 0-114-04-2000C PN 17 EA 4 661,396.04

12 A093290040010025 IPCV SM PILOT VALVE ASSY EA 4 661,396.04

13 A115090380050122 PMP WTR WEIR RING SECTION SECOND STAGE EA 2 444,182.13

14 A036020130010003 LUBRCNT OIL SP HYDR IOC SERVO SYS HLP 32 L 2730 408,004.01

15 A075170140170006 VLV CL2500WC9 65NB VALVE ASSY MANUAL BW EA 1 407,818.95

16 A066010080030003 SIZE 8 X 6 MODEL-67-91222 - PLUG SEAL RI EA 3 382,653.00

17 A036020160020011 LUBRCNT OIL TURB IOC SERVO PRIME 46 L 2310 371,576.49

18 A115090380050040 CU-MS GASKET 605 O / D X546 I / D X 3 TH EA 2 306,658.40

19 A023010020100005 FRF SUPERFINE FILTER (SIZE 18"x5"x1") EA 14 288,456.00

20 A023010020100002 ANY MAKE AS PER IS STANDARD DUPLEX FILER EA 2 257,308.50

140

21 A036020160010008 LUBRCNT OIL TURB HPCL TURBINOL 46 L 1470 241,403.40

22 A035020050070016 LONG TRAVEL DRIVE SHAFT EA 3 209,322.96

23 A118080080010011 TBTDJ2M CIRCLIP PN 2480061150 EA 33 195,525.00

24 A093290010100022 MODULE SHFT SEAL SCREW HEX PM 12 X 60 EA 55 192,555.00

25 A115090380050108 PMP WTR WEIR OUTLET GUIDE EA 1 179,416.73

26 A066010080030002 SIZE 8 X 6 MODEL-67-91222 - BONNET SEAL EA 2 174,277.20

27 A133300020010021 M/S CEP EB SILICONE CARBIDE FACE EA 2 161,700.39

28 A115090380050135 PMP WTR WEIR SHEAR RING EA 10 143,694.48

29 A093590010010014 MVNG BLADE CLAMPING PIECE P.N.008 EA 202 128,669.41

30 A075010030020006 VLV ENER SEAL RING (PLUG) PN 13 EA 1 127,551.00

31 A107080020010006 CR PLAIN SHEET SIZE 5000 X 1250 X 3.15MM TO 2 123,200.00

32 A075190190100008 VLV 40NB ASSY RISING SPINDLE MANUAL SW EA 4 121,961.31

33 A075170100030005 VLV CL150WCB CS 150NB VLV ASSY MANUAL FL EA 3 117,959.51

34 A133300010010001 M/S CEP EN7J40D EB CARBON FACE (PN-B) EA 3 106,150.28


36 A093510100010001 BLADDER 50L CAPACITY/35 KG/CM2 PRESSURE EA 1 100,974.90

37 A107010010010110 ANGLE MS EQUAL 50 X 50 X 6 MM TO 3 96,900.00


39 A115090380050098 PMP WTR WEIR OIL THROWER EA 3 83,910.94

40 A088010040010017 TG500MW SEALING HALF RING BOTTOM EA 124 82,138.00

41 A093290010100028 TBNSTEAM MODULE SHFT SEAL SEALING RING EA 120 80,856.00

42 A075170100030005 VLV CL150WCB CS 150NB VLV ASSY MANUAL FL EA 2 78,639.67

43 A031020010020003 SPONGE RUBBER BALL DIA 29 MM MEDIUM ELAS EA 4400 75,488.55

44 A093530060040023 TEST VALVE FOR SERVOMOTOR LINER ITEM 01 EA 1 74,959.80

45 A093510090010004 STEAM TURB OIL REGEN SYS FULLER EARTH KG 1950 70,609.50

46 A093560010030009 BRG HOSE EXTR BRG DRG 1142140100000001 EA 1 70,541.26

141

47 A027010010230006 JOINTINGSHET SUPER MET1525X1650MMTH3.0MM KG 214 70,245.94

48 A133050010010003 M/S BOOSTR BFP EB SEAL FACE CARBON PN 11 EA 1 63,328.15

49 A036020020010027 LUBRCNT OIL CIRC IOC SERVO SYSTEM 68 L 420 62,654.38

50 A115090380050099 PMP WTR WEIR OIL THROWER NDE EA 2 62,318.31


52 A133300010010005 M/S CEP EN7J40D EB MATING RING ( PN-2) EA 1 58,933.64

53 A078010010030001 CHEM ADH COMP ST-SEL JOINT PASTE TYPE B KG 19 58,860.48

54 A075010020040007 PTFE BACKUP RING P.N. 079003552-940 EA 3 56,132.71

55 A093390010040015 MODULE CASING STUD BM 80X 6X 600-25X 551 EA 2 53,915.00

56 A003060010020015 ACT HYD SLZ ASM100-10 PSTN SEAL PN 6078 EA 3 53,172.89

57 A066010080030009 8 X 6 -67-91222 - SEAT GASKET EA 3 45,379.80

58 A115030230020039 PMP CHEM SHAPO DP-60-PNM WORMWHEEL EA 3 45,000.00

59 A133050020010010 BFP PUMP FA-1B-75 INSERT MOUNT VITON PN6 EA 8 44,450.76

60 A133050020010009 BFP PUMP MOD FA-1B-75 INSERT CARBON PN.2 EA 3 42,656.66

61 A093390010070034 TRBN STM FITTED KEY PN 36 EA 2 41,642.00

62 A115030230010022 PMP CHEM SHAPO MAIN HD,NUT,PLNGR ASY EA 1 41,600.00

63 A115030230010046 PMP SHAPOTOOL DP30PNM CRANK SHAFT EA 2 40,000.00

64 A036020020010023 LUBRCNT OIL CIRC IOC SERVO SYSTEM: 176 L 250 39,943.46

65 A107040010030014 MS ISMC CHANNEL SIZE 150 X 75 MM TO 1 39,205.95

66 A003060010010006 ACT HYD SLZ ASM250-10 PSTNROD SEL PN6021 EA 3 37,151.06

67 A027010010240007 GSKT&PCK JNT SHT1525 X 1650 MM TH 3.0 MM EA 150 36,045.82

68 A093530020030020 TUR MOP RING D185 PN 41 EA 2 35,326.89

69 A003060010010008 ACT HYD SLZ ASM250-10 SCRPR RNG PN 6023 EA 3 34,212.56

70 A035020050070017 MICRO COUPLING GEARBOX SIDE HUB EA 1 33,879.78

71 A027010010230007 JOINT SHEET 1525X1650MMTH4.0MM KG 100 32,511.63

72 A093250010050002 MODULE CASING BOLT HEX PM 56 X 200 EA 7 31,925.93

142

73 A118080080080007 COMPR TBTDJ2M VLV SEAT DEL LP 2480070150 EA 12 31,920.68

74 A028040050010026 GLAND RING GRAFOIL 50 X 32 X 10 MM EA 56 31,864.00

75 A003060010020008 ACT HYD SLZ ASM100-10 SCRPR RNG PN 6023 EA 3 30,434.48

76 A118080080050009 COMPR TBTDJ2M PISTON RING LP 2481033550 EA 6 30,223.48

77 A035020050070018 MICRO COUPLING MOTOR SIDE HUB EA 1 30,115.36

78 A027010010240010 JOINTG SHEET STYLE 54 1525 X 1650 X 4 MM KG 120 29,449.64

79 A075220030110006 VLV NRV FLAP CL150WCB CS SWING 80NB ASSY EA 1 29,161.00

80 A070040040270001 WELDSOLBRAZ ELECTRODE CI CINOD160 2.5MM KG 5 28,631.96

81 A133050010010004 H75F2/100E3 O-RINGS SET 1.2,3,5,7 ST 3 28,614.89

82 A003010040010004 ACTUAT MOTORD ROTORK BUSH EA 6 28,554.24

83 A028120010030042 GSKT SEAL RING GRAFOIL ANG 680X635X40 MM EA 5 28,521.75

84 A010010070020002 SPC NO 4500 SET OF 27 BELT EA 29 28,146.03

85 A118080080080012 COMP TBTDJ2M VALVE GUARD DELIVERY H P EA 53 27,354.36

86 A078020130070001 LUBRICANT MOLYKOTE MOLYKOTE 1000 EA 17 26,010.00

87 A118080080050018 COMPR TBTDJ2M GUIDE RING HP 2480038751 EA 16 25,344.00

88 A093590010010016 MVNG BLADE LOCKING PLATE P.N.010 EA 10 25,221.98

89 A003060010010007 ACT HYD SLZ ASM250-10 GUIDE RNG PN 6022 EA 4 25,187.16

90 A070040090100001 ELECTRODE SPRG ST UNILOY 624 2.5MM KG 10 24,474.65

91 A133300010010019 MECH SEAL CEP EN-7-J-40-D CUP EA 1 24,437.98


93 A078020130070008 MOLYKOTE HSC PLUS PASTE KG 7 23,669.10

94 A078010010050040 CHEM ADH COMP SEAL HY UBLUN-SET ST 100GM EA 47 23,011.20

95 A093250010010013 TBNSTEAM 500MW MODULE CASING FITTED KEY EA 2 22,942.00




143

99 A115090380050005 PMP WTR WEIR BAFFLE PLATE EA 2 22,474.24

100 A115090380050079 IMPELLER WEAR RING KICKER STAGE EA 1 22,285.24

101 A115050020010167 PMP OIL ALF/LVL MAB103 WTR ADNG DVIC CMP EA 1 21,234.51

102 A093510010020007 MOP BRG BUSH EA 1 19,590.01

103 A093240010090001 TBNSTEAM 500MW MODULE ATM DIAPH DIAPHRAG EA 2 19,246.34

104 A115030160010026 PMP MC2/R LIQUID HEAD 25PBLH01 EA 1 18,872.54

105 A115080050020008 PMP VACCUM SIEMENS RETAINING RING EA 4 18,660.00

106 A003060010020006 ACT HYD SLZ ASM100-10 PSTNROD SEL PN6021 EA 2 18,657.15

107 A027010010220007 JOINTINGSHET OIL NONMET1525X1650MMTH3MM KG 71 18,413.46

108 A118080080040013 T-BTD-JM 06 PIECE PACKING TAN 2480102050 EA 20 16,000.00

109 A075010030020012 VLV SEAT RING GASKET PN 20 EA 1 15,126.60


111 A003060010020007 ACT HYD SLZ ASM100-10 GUIDE RNG PN 6022 EA 8 13,526.43

112 A115090380070012 DE OIL GUARD IN BOARD PN 11 EA 1 13,361.04

113 A028040050010019 GLAND RING GRAFOIL 41.3 X 17.2 X 12 MM EA 23 13,087.00

114 A118080080080006 COMPR TBTDJ2M VLV SEAT SUC HP 2480065150 EA 5 12,637.57

115 A115080040020014 PMP VCUM FIXED BEARING P/N 120 EA 1 12,500.00

116 A114010050020081 FASTNRS M 30 X 110 EA 13 11,850.16

117 A093390010070021 MODULE SHFT SEAL SCREW HEX AM 36 X 180 EA 10 11,720.64

118 A115090380050154 PMP WATER LUB OIL FILTER EA 9 11,704.50

119 A003010040010054 ACTUAT MOTORD ROTORK K1000 THRUST BRG EA 1 11,503.64

120 A118080080020002 AIR COMPR TBTDJ2M BRG PN 2510041850 EA 5 11,496.45

121 A036020160020009 LUB OIL TURBINE IOC SERVO PRIME 68 L 70 11,256.80

122 A093560010030006 BRG HOSE DN 16x2500 DRG 011814-02000/50 EA 2 11,025.59

123 A023010020100003 ANY MAKE AS PER IS STANDARD GOVERNING OI EA 3 10,924.20

124 A072020010070058 BRG MET BALL SADR 2309 ETN9C3 EA 4 10,264.00

144


126 A028100030010182 SPIRAGATE SS304 ASBT 5285 X 5025 X 45 MM EA 8 10,000.00

127 A028100030010222 GSKT SS 304 ASBESTOS FILL 95 X80X 3.2 MM EA 8 10,000.00

128 A115030230020038 PMP CHEM SHAPO DP-60-PNM WORM SHAFT EA 1 10,000.00


130 A115090380050001 PMP WTR WEIR AIR VENT 3 / 4" NPT EA 2 9,831.97

131 A118080080080031 COMP TBTDJ2M VALVE GUARD SUCTION H P EA 9 9,432.00

132 A003010040040029 ACTUAT MOTORD K600 L_SWITCDRIVESHFT EA 10 9,151.58

133 A072020010070060 BRG MET BALL SADR 2310 C3 EA 3 8,935.20

134 A114070050020001 FASTNRS M 12 X 40 EA 346 8,650.00

135 A115090380050061 PMP WTR WEIR FLOATING SEAL EA 2 8,571.25

136 A003010040010005 ACTUAT MOTORD ROTORK CENTRE COLUMN EA 1 8,520.08


138 A072020010030016 BRG MET BALL DRANGCONT 3310 A EA 3 8,172.57

139 A115050400010027 PMP OIL SHARPLES AS 12 FLEXIBLE COUPLING EA 3 8,100.00

140 A072020010080065 BRG MET BALL SRACONT 7318 BEP EA 1 7,800.39

141 A036010010050001 LUBRCNT GRS EQ&MC/NRY IOC SERVO GEM 03 KG 40 7,559.05

142 A036020100010018 LUBRCNT OIL IND GEAR IOC SERVOMESH SP68 L 50 7,548.00

143 A028100030010195 GSKT SS 304 ASBESTOS FILL 65 X25X 3.2 MM EA 6 7,500.00

144 A027010010220005 GSKT&PCK JNT SHT1525 X 1650 MM TH 1.5 MM KG 30 7,282.86

145 A134010060050003 CLOTH GENERAL CANVAS CLOTH M 22 7,068.60

146 A119020180010002 NORMEX 128 COUPLING SPIDER EA 2 7,038.00

147 A003010040040004 ACTUAT MOTORD ROTORK K600 BUSH EA 3 6,884.44

148 A115090380050003 PMP WTR WEIR BAFFLE DE EA 1 6,500.00


150 A028040050010007 GLAND RING GRAFOIL 26.3 X 13.5 X 6.2 MM EA 11 6,259.00

145

151 A118080080100001 AIR COMPR TBTDJ2M OIL WIPER RING EA 43 6,235.00

152 A078010010030008 STEAM SEAL RTV 1080 NEUTRAL EA 35 5,997.60

153 A036020060010011 LUBRCNT OIL ENGINE IOC SERVO PREM 15W40 L 32 5,712.00




157 A072020050020006 BRG MET SPHR SEALGN 22207 E EA 3 5,274.60

158 A001020010010005 ABR COMP CARLAP MESH SIZE80,200GMTIN PAC 10 5,148.95

159 A075430200020003 BALL VALVE 40MM(CS BODY) EA 3 5,102.89

160 A133300010010020 MECH SEAL CEP EN-7-J-40-D T-WASHER EA 1 4,771.80

161 A075430200020006 BODY CS COMPLETE BALL VALVE 15 MM EA 7 4,769.52

162 A003010040010029 ACTUAT MOTORD K1000 L_SWITCHDRIVESHFT EA 4 4,655.15

163 A003010040040005 ACTUAT MOTORD K600 CENTRECOLACTUAT EA 1 4,628.40

164 A027070010090001 GSKTMTRL 1000 MM X 2000 MM KG 50 4,608.11

165 A072020010080039 BRG MET BALL SRACONT 7309 BEP EA 3 4,520.85

166 A027130060070002 PTFE SHEET TH 3.0 MM 300 MM X 300 MM EA 6 4,279.72

167 A003010040010035 ACTUAT MOTORD ROTORK K1000 OIL SEAL EA 2 4,279.37

168 A107070010010027 RECTANGULAR TH 0.80 MM, 14" X 48" EA 6 4,180.20

169 A028040050010062 GLAND RING GRAFOIL 85 X 60 X 12.5 MM EA 7 3,983.00

170 A115030160020014 PMP CHEM MEATCHEM MC3/R PLNGR RNG PI D20 EA 4 3,926.61

171 A075430200020005 BALL VALVE CS COMP ASLY SIZE-20 MM EA 4 3,813.57

172 A107070010010025 RECTANGULAR TH 0.70 MM, 14" X 48" EA 6 3,799.79

173 A027190010010001 GSKTMTRL 3 MM THICK KG 14 3,635.26

174 A075430200020004 BALL VALVE CS COMP ASLY SIZE-25 MM EA 3 3,607.89

175 A115050020010171 PMP OIL ALF/LVL WORMWHEEL, PN:515799-04 EA 1 3,500.00


146


178 A115050400010035 PMP OIL SHARPLES AS 12 IDLER SPINDLE EA 1 3,200.00

179 A093560010090032 SHIM PN 118180200000016 EA 4 3,132.07


181 A028020060010001 GSKT H2 COOLR SILICON RUBBR 245x214x15 ST 1 3,060.00

182 A115090380050149 NEOPRENE RUBBER GASKET FOR CI QUENCH FIL EA 6 3,037.00

183 A114010050010048 FASTNRS M 24 X 60 EA 40 3,030.92

184 A130060050010003 DUMMY PLUG TAPER SIZE 30 X 26.5 X 50 MM EA 22 3,029.93

185 A115080050020015 PMP VACCUM SIEMENS THREADED PIN EA 2 3,000.00

186 A070040080030001 ELECTRODE MS CHROMOTHERM II 2.5MM KG 6 2,959.97

187 A115050020010206 PMP OILMAB-103 O-RING PN 66554 EA 20 2,900.00

188 A118080080040014 T-BTD-JM 03 PIECE PACKING RAD 2480102150 EA 3 2,850.00


190 A001020010010006 ABR COMP CARLAP MESH SIZE140,200 GMTIN PAC 8 2,801.27

191 A107070010010019 RECTANGULAR TH 0.45 MM, 14" X 48" KG 6 2,796.84

192 A093560010090047 SHIM S=2 PN 118180200000011 EA 3 2,743.76

193 A028120010030021 BONNET SEAL RING 150 X 135 X 15 MM EA 5 2,717.60

194 A114030080040014 FASTNRS M 4 KG 70 2,660.00

195 A072020020050007 BRG MET CYLROL NUTYPE NU 211 EA 2 2,575.05

196 A133300020010014 M/S CEP EN7J40D EB "O" RING - 25 EA 1 2,565.00

197 A093590020030041 PLATE PN 0107440200000048 EA 2 2,553.70

198 A028120010030004 GSKT SEAL RING GRAFOIL ANG 105 X91X14 MM EA 3 2,535.00

199 A028080020030004 SERRTD METAL RING CIRCLR 104 X86X 3.2 MM EA 2 2,512.00

200 A028080020030006 SERRTD METAL RING CIRCLR 105 X95X 3.2 MM EA 2 2,512.00

201 A028100030010087 SPIRAGATE SS304 ASBT 149 X 133 X 4.5 MM EA 2 2,500.00


147

203 A115030230010017 PMP CHEM SHAPO DP-30-PNM GLAND NUT EA 2 2,500.00

204 A115050400010008 PMP OIL SHARPLES AS 12 BEARING SLEEVE EA 1 2,500.00

205 A093560010090044 SHIM S=0.5 PN 118180200000012 EA 3 2,461.59

206 A118080080030002 COMPR TBTDJ2M SUC FILTER 500X500X50 EA 1 2,450.00

207 A027010010030006 1525 X 1650 MM, STYLE 59 / K SOE OIL KG 12 2,423.52

208 A114070050010093 FASTNRS M 8 X 20 EA 307 2,410.48

209 A028040020020092 GLAND RING GRAFOIL 55 X 28 X 14 MM ST 50 2,318.54

210 A114010050010047 FASTNRS M 24 X 100 EA 25 2,282.27

211 A118080080080005 TBTDJ2M VLV SPRING DEL HP 2460067250 EA 11 2,264.00

212 A070040080030002 ELECTRODE MS CHROMOTHERM II 3.15MM KG 5 2,245.84

213 A107070010010166 SHIM SS N-M RECTAN TH 0.02MM 48X14 INCH EA 5 2,177.70

214 A114010050010040 FASTNRS M 20 X 50 EA 45 2,169.98


216 A093560010090033 SHIM PN 118180200000017 EA 4 2,143.24

217 A027010010220006 STYLE 59 OIL NON METALLIC 1525X1650MM TH KG 11 2,130.92


219 A115030160020032 PMP MC3/R LOCK NUT 35PA23L EA 3 2,100.00

220 A114030120010007 FASTNRS M 16 EA 270 2,025.66

221 A114010090010146 FASTNRS M 33 X 175 KG 25 1,989.00

222 A114010090010145 FASTNRS M 33 X 150 KG 25 1,983.00

223 A115050020030070 PMP OIL ALF/LVL GLASS TUBE73921 EA 1 1,912.28

224 A093560010090042 SHIM S=0.2 PN 118180200000013 EA 3 1,884.39

225 A070040100060001 WELDSOLBRAZ ELECTRODE SS RUTOX B 2.5MM KG 2 1,880.00

226 A072020010090008 BRG MET BALL SRDG 6309 EA 3 1,845.92

227 A093560010090034 SHIM PN 118180200000018 EA 4 1,813.24


148

229 A114010090010117 FASTNRS M 24 X 100 KG 20 1,724.29


231 A078010010020017 CHEM ADH COMP STEEL M SEAL-FASTCURE 1KG KG 8 1,723.82


233 A107070010010123 SHIM RECT TH 0.30 MM, 48 X 14 INCH KG 5 1,677.90

234 A047010080100029 VITON O-RING CS DIA 4 MM ID 297 MM EA 4 1,671.19

235 A114010050010030 FASTNRS M 16 X 50 EA 94 1,665.86

236 A072020080010044 METRIC ADAPTER SLEEVE WITH LOC NUT H3124 EA 2 1,650.02

237 A093560010090035 SHIM PN 118180200000019 EA 4 1,647.66

238 A072020060010137 METRIC TAPER ROLLER SINGLE ROW 30306 J2 EA 2 1,645.60

239 A093560010090040 SHIM S=0.1 PN 118180200000014 EA 3 1,640.67

240 A078020060030001 CHEM CNTCT-CL KLINIT SPRAY TIN 350 ML EA 7 1,612.72

241 A115050020010173 PMP OILMAB-103 BUSHING PN 523644-03 EA 4 1,600.00


243 A010010030380001 BELT V-BELT C NO 204 SET OF 4 BELT EA 3 1,580.73

244 A115030160010021 PMP CHEMICAL METACHEM CIRCLIP FOR CONTRO EA 20 1,580.00

245 A078020160070001 CHEM 1 GALLION TIN PACK EA 1 1,547.34

246 A027190030010002 GSKTMTRL 5 MM X 50 MM IN 5 KG PK KG 5 1,538.14

247 A115030160020007 PMP CHEM MEATCHEM MC3/R ECCENTRIC 35PA13 EA 1 1,499.00

248 A028120010030020 GSKT SEAL RING GRAFOIL ANG 145X127X18MM EA 4 1,435.25

249 A114010090010088 FASTNRS M 20 X 100 KG 17 1,427.93

250 A075430180010001 VLV BALL SS 1/2INCH VALVE ASSY EA 1 1,418.37

251 A114010050010120 FULL THREAD M 20 X 90 EA 30 1,415.25

252 A029090020010011 POWDER FORM DETERGENT SURF 0.5 KG PACK EA 20 1,372.80

253 A115050020010221 PMP OILMAB-103 SPLIT PIN PN 16434 EA 18 1,350.00

254 A072020010030008 BRG MET BALL DRANGCONT 3305 AP EA 1 1,342.91

149


256 A047010080050015 O-RING VITON CS DIA 3 MM ID 92 MM EA 10 1,304.29

257 A114010090010078 FASTNRS M 18 X 50 KG 14 1,261.10

258 A028080020030012 SERRTD METAL RING CIRCLR 360 X 345 X 2MM EA 1 1,256.00



261 A115050020010226 PUMP OILMAB-103 WEAR GASKET PN 535743-02 EA 4 1,250.00


263 A114030080040004 FASTNRS M 16 KG 15 1,233.10

264 A031020010010005 DUMMY PLUG 31.5X 27.5X 45 MM L BRASS EA 7 1,207.41

265 A072020010090236 BRG MET BALL SRDG 6310 ZC3 EA 2 1,195.05

266 A114010090010014 FASTNRS M 12 X 100 KG 13 1,171.84

267 A114030120010005 FASTNRS M 12 EA 220 1,169.04

268 A115090380050125 PMP WTR WEIR SET PIN M 24X110 LG EA 2 1,144.02




272 A028040020020057 GLAND RNG GRAFOIL 64X44X10 MM EA 35 1,123.60


274 A078020200030001 CHEM CLG AGNT DET PWDR SURF 1/2 KG PKT EA 18 1,101.59

275 A028040020020053 GRAFOIL GLAND RING SIZE 75 X 50 X12.5 MM EA 20 1,070.10

276 A027130060050002 PTFE SHEET TH 2.0 MM 300 MM X 300 MM EA 2 1,060.80

277 A114010090010049 FASTNRS M 16 X 100 KG 13 1,042.20

278 A107070010010124 SHIM RECT TH 0.15 MM, 48 X 14 INCH KG 5 1,030.20

279 A114010050010013 FASTNRS M 12 X 50 EA 95 1,020.54

280 A114010090010025 FASTNRS M 12 X 50 KG 12 1,000.14

150

281 A115050020010236 PMP ALPHALAVAL MAB103 GASKET PN-62812 EA 8 1,000.00

282 A115050400010025 PMP OIL SHARPLES AS 12 FEED NOZZLE EA 1 1,000.00

283 A047010080050037 O-RING VITON CS DIA 3MM ID 66 MM EA 10 996.78

284 A027130040010006 PTFE BAR ROUND 30 MM EA 2 991.44

285 A072020010090048 BRG MET BALL SRDG 6311 C3 EA 1 972.63

286 A072020010100011 BRG MET BALL THRST 51111 EA 1 968.64

287 A078010010050013 CHEM ADH COMP SEAL ARALDITE 1.8 KG EA 1 968.27

288 A114060100020043 FSTNR HEX SOC CAP SCREW M 20X150 EA 8 960.00

289 A119020040030018 FLEXIBLE LOVEJOY RUBBER SPIDER L 100 EA 9 937.18

290 A107070010010006 RECTANGULAR TH 0.07 MM, 14" X 48" KG 6 936.36

291 A114030080040002 FASTNRS M 12 KG 11 904.34

292 A003010010550009 AUMA SA12A32 THRUST BRG PN 4403, 4404 ST 1 897.00

293 A028100030010054 SPIRAGATE SS304 ASBT 100 X 60 X 32 MM EA 1 895.00

294 A010010020080001 BELT VBLT TYPB 62 SET OF 2 BELT EA 8 889.77

295 A114060100020045 FSTNR HEX SOC CAP SCREW M 24X140 EA 6 870.00

296 A115050020010031 PMP OIL ALF/LVL CAP NUT, PN: 522997-01 EA 1 858.92

297 A115050400010039 PMP OIL SHARPLES AS 12 MALE CLUTCH B-512 EA 1 850.00

298 A115090300110017 PMP WATER SAM HEX SCREW EA 1 840.00

299 A036020110040026 LUBRCNT OIL LUB IOC SAE-30 L 5 837.90

300 A093560010090046 SHIM S=1 PN 118180200000010 EA 1 819.75

301 A114010090010021 FASTNRS M 12 X 30 KG 10 794.02

302 A047010080100028 VITON O-RING CS DIA 4 MM ID 228 MM EA 4 776.21

303 A114190060010008 FASTNRS M 24 KG 11 769.87

304 A028040020020089 GLAND RING GRAFOIL 48 X 30 X 9MM ST 40 760.96

305 A115090390120002 PMP WATERIAK5089 BEARING FOR PACKING BOX EA 3 750.00

306 A098130020010003 HNDTOOL HKSAW BLAD HSS 1/2"X12"X18TPI EA 19 718.80

151

307 A114030120010011 FASTNRS M 24 EA 25 711.99

308 A114190060010004 FASTNRS M 16 KG 10 692.75

309 A003010040010006 ACTUAT MOTORD ROTORK CIRCLIP EA 1 690.90

310 A001040030060001 ABR EMRY TAPE ROUG 50MMWIDTH50MTRROL EA 1 684.18

311 A114030120010013 FASTNRS M 30 EA 12 656.29

312 A028120010030015 GSKT SEAL RING GRAFOIL ANG 120X107X14 MM EA 3 652.76

313 A078020160040002 CHEM 5 LTR TIN PACK EA 1 650.07

314 A114010090010198 FASTNRS M 6 X 40 KG 7 649.32

315 A114030120010004 FASTNRS M 10 EA 175 647.24

316 A078010010090001 CHEM ADH COMP AQB AQUASEAL FAST CURE 1KG EA 1 605.21

317 A114010090010216 FASTNRS M 8 X 50 KG 8 604.33

318 A078010010050014 CHEM ADH COMP SEAL ARALDITE 180 GM EA 3 600.81

319 A114010050010006 FASTNRS M 10 X 50 EA 75 590.68

320 A001040030040001 ABR EMRY TAPE MED 50MMWIDTH50MTRROL EA 1 587.13

321 A111160010010002 CS ELBOW 90 DEG 100 MM NB EA 1 573.24

322 A114010090010008 FASTNRS M 10 X 50 KG 7 569.95

323 A028040050010047 GLAND RING GRAFOIL 68 X 44 X 10 MM EA 1 569.00

324 A078020160070002 CHEM 340 GM SPRAY CAN EA 3 551.06

325 A115050400010014 PMP OIL SHARPLES AS 12 BOWL BOSS SLEEVE EA 1 550.00

326 A111160070010001 CS UNION 1 1/2 IN HEVY DUTY MS SOCKT TYP EA 1 542.64

327 A072020010090009 BRG MET BALL SRDG 6310 EA 1 541.58

328 A119020040030009 COUPL COUPLING NO L 95 EA 1 530.73

329 A115050400010005 PMP OIL SHARPLES AS 12 BEARING FILLER B- EA 1 520.00

330 A133300010010011 M/S CEP EN7J40D EB SPRNG (PT NO-1C) ST 2 512.00

331 A078020050060001 CHEM CLN PEN DVP FC CLEANER PC-21B EA 3 506.85

332 A078020160040001 CHEM 1 / 2 LTR TIN PACK EA 7 502.76

152

333 A114030120010009 HT 12.9 GR METRIC NUT PLAIN M 20 EA 20 501.47

334 A115050400010026 PMP OIL SHARPLES AS 12 FEMALE CLUTCH EA 1 500.00

335 A028120010030010 GSKT SEAL RING GRAFOIL ANG 112 X96X13 MM EA 1 494.70



338 A047010080080009 VITON O-RING CS DIA 3.55 MM ID 53 MM EA 10 466.58

339 A114010050020014 FASTNRS M 12 X 55 EA 50 437.95

340 A114010050020007 FASTNRS M 10 X 80 EA 20 433.92

341 A114190060010001 FASTNRS M 10 KG 6 428.17

342 A047010080050007 O-RING VITON CS3MM ID 28 MM EA 13 427.34

343 A114030080040018 FASTNRS M 6 KG 4 422.24

344 A114190060010020 FASTNRS M 8 KG 6 419.24

345 A114030080040019 FASTNRS M 8 KG 5 418.51

346 A028120010030040 GSKT SEAL RING GRAFOIL ANG 64 X44X 10 MM EA 10 416.15

347 A003010040200003 ROTORK K 150 HAND WHEEL RETAINER EA 1 412.00

348 A114010090010068 FASTNRS M 16X 80 KG 5 405.82

349 A114010090020076 FASTNRS M 16 X 100 KG 5 402.31

350 A115050400010021 PMP OIL SHARPLES AS 12 DRAG BUSHING-6372 EA 1 400.00

351 A133300010010008 M/S CEP EB SOCKET EST SCREW P NO12 EA 2 400.00


353 A114010090010011 FASTNRS M 10 X 75 KG 5 391.17

354 A114010090010196 FASTNRS M 6 X 30 KG 4 376.45


356 A029080010010001 HARDWR MARK IDENTI BLUE PASTE TUBESIZE EA 9 363.17

357 A003010040040078 ACTUAT MOTORD ROTORK TORSION SPRG EA 2 363.09

358 A115050020010099 PMPOILALF/LVL ORING RUB3034-73D3X292MM EA 1 350.00

153


360 A114060100010020 FASTNRS M 12 X 50 EA 30 320.49





365 A114010050010031 FASTNRS M 16 X 60 EA 15 305.42

366 A028040020020100 GLAND RING GRAFOIL 74 X 48 X 13 MM ST 5 303.19


368 A114030120010006 FASTNRS M 14 EA 50 287.93


370 A115050020010180 PUMP OILMAB-103 GASKET PN 14161 EA 2 280.00

371 A047010080080008 VITON O-RING CS DIA 3.55 MM ID 42.5 MM EA 6 279.95


373 A028040020020087 GLAND RING GRAFOIL 38 X 22 X 8MM ST 23 273.47

374 A114190060010018 FASTNRS M 6 KG 4 265.32

375 A003010010030010 ACTUATOR AUMA SA6A22 WORM GEAR PN 26 EA 1 258.00

376 A115090190820006 PMP KBL RKB65-19L4 OIL SEAL 65 X 54 X 12 EA 1 256.00

377 A003010040150010 ROTORK ACT K60 CIRCLIP FOR CENTER COLUMN EA 2 250.00

378 A114030120010003 FASTNRS M 8 EA 125 224.51

379 A078010010070004 CHEM ADH COMP GSKT SPEB-7 500ML TIN EA 2 211.17

380 A003060010010018 ACT HYD SLZ ASM250-10 O-RNG PN 6080 EA 1 198.23

381 A078020050060003 CHEM CLN PEN DVP FC PENETRANT PP-15B EA 1 192.40

382 A078010010050015 SEALENT ANABOND 666 100 GM PKT EA 2 191.72


384 A119020040030010 FLEXIBLE LOVEJOY COUPLING PAD FOR L 95 ST 2 179.52

154

385 A078020050060002 CHEM CLN PEN DVP FC DEVELOPER PD-31B EA 1 171.10

386 A027130070010001 PTFE TAPE ROLL 12.5 MM W 12 M EA 10 170.10

387 A098130020010004 HNDTOOL HKSAW BLAD HSS 1/2"X12"X24TPI EA 5 166.01

388 A114010090010031 FASTNRS M 12 X 80 KG 2 156.79


390 A115050400010010 PMP OIL SHARPLES AS 12 BEARING SPACERS A EA 1 150.00

391 A072020080010028 BRG MET SLV ADPTSLV H 2308 EA 2 140.00

392 A114070050010079 FASTNRS M 6 X 12 EA 35 140.00

393 A072020010090086 BRG MET BALL SRDG 6200 2Z EA 2 136.99



396 A115090191430018 PMP KBL BHR28/2STG BRG NUT PN 33501A3 EA 1 126.00

397 A032010020010007 HOSE RUBBER SSBRD 3/8"X3/8" BSP,L500MM EA 2 125.67

398 A072020010090098 BRG MET BALL SRDG 6204 2Z EA 1 116.40


400 A111160010010005 CS ELBOW 90 DEG 90 DEG 25 MM NB EA 2 97.92

401 A114090050010005 FASTNRS M 10 X 25 EA 20 96.06


403 A114030080040001 FASTNRS M 10 KG 1 85.69


405 A115030160010022 PMP CHEMICAL METACHEM CIRCLIP FOR CRANK EA 1 80.00

406 A114010050010023 FASTNRS M 14 X 50 EA 3 78.21


408 A114190060010002 FASTNRS M 12 KG 1 70.91

409 A114030120010002 FASTNRS M 6 EA 50 65.59

410 A111030130020006 MS CONECTR 3/8"BSP(M)X3/8"BSP(M) EA 3 56.06

155

411 A114090050010079 FASTNRS M 6 X 10 EA 20 41.26

412 A098130020020001 HNDTOOL HKSAW BLAD ALOY 1/2"X12"X18TPI EA 5 40.51

413 A114090050010094 FASTNRS M 8 X 16 EA 20 30.60

414 A098130020020002 HNDTOOL HKSAW BLAD ALOY 1/2"X12"X24TPI EA 5 22.53

415 A115080050020020 PMP VAC SIEMENS COUPLING PADS EA 1 12.00

416 A115090380050117 PUMP SHAFT EA 1 1,947,946.65

417 A115090380050086 LABYRINTH BUSH (DE/NDE) EA 2 419,069.72

418 A115090380050042 3RD STAGE DIFFUSER EA 1 408,895.37

419 A115090380050173 DIFFUSER 1ST STG EA 1 408,895.37

420 A115090380050073 IMPELLER 4TH STAGE EA 1 371,286.66

421 A115090380050072 IMPELLER 1ST STAGE EA 1 332,160.59

422 A115090380050077 IMPELLER 3ED STAGE EA 1 327,347.34

423 A115090380050065 GLAND SLEEVE NDE EA 1 312,371.49

424 A115090380050076 IMPELLER SECOND STAGE EA 1 286,595.90

425 A115090380050075 IMPELLER KICKER STAGE EA 1 273,001.61

426 A115090380050168 SET OF FASTERNERS EA 1 166,464.00

427 A115090380050172 PMP BFP THRUST PADS (16 NOS.) EA 1 160,490.38

428 A115090380050171 BFP PMP CU-MS GSKT 605 X 546 X 4.2 EA 1 153,902.32

429 A115090380050033 CASING WEAR RING EA 4 105,489.04

430 A115090380050006 BALANCE DRUM EA 1 99,931.15

431 A115090380050143 THRUST COLLAR EA 1 99,115.64

432 A115090380050094 IMPELLER WEAR RING (NECK) EA 4 94,913.36

433 A115090380050153 DISC SPRING EA 1 92,562.30

434 A115090380050078 IMPELLER WEAR RING (EYE) EA 4 85,100.24

435 A115090380050064 GLAND SLEEVE DE EA 1 66,203.56

436 A115090380050044 DIFFUSER WEAR RING EA 4 63,109.64

156

437 A115090380050157 SET OF OIL GUARDS EA 1 56,637.53

438 A115090380050009 BALANCE DRUM RESTRICTION BUSH EA 1 53,983.18

439 A115090380050156 INTERSTAGE TAP OFF BUSH EA 1 44,368.69

440 A115090380050085 JOURNAL BEARING DE EA 1 36,088.70

441 A115090380050160 JOURNAL BEARING NDE EA 1 34,118.56

442 A115090380050088 METAFLEX GSKT EA 1 30,581.82

443 A115090380050034 CASING WEAR RING KICKER STAGE EA 1 24,735.95

444 A115090380050176 SET OF KEYS SET 1 22,054.20

445 A115090380050133 SHAFT NUT THROWER M 115 X 2 LH (NDE) EA 1 18,707.32

446 A115090380050175 ROTOR LOCKING CHANNEL ASSLY SET 1 15,542.96

447 A115090380050002 SET OF O RINGS & BACK UP RINGS EA 1 15,001.06

448 A115090380050134 SHAFT NUT THROWER M 140 X 2 RH (DE) EA 1 14,833.04

449 A115090380050114 PLUG FOR OUTLET GUIDE EA 1 14,772.11

450 A115090380050119 RESTRICTION BUSH (DE/NDE) EA 1 10,713.14

451 A115090380050145 THRUST COLLAR NUT M 80 X 2 LH EA 1 8,212.13

452 A115090380050110 PACKING RING FOLLOWER EA 1 6,826.30

453 A115090380050008 BALANCE DRUM LOCK WASHER EA 1 5,368.29

454 A115090380050067 SET OF LOCKING SCREWS EA 1 2,415.46

455 A115090380050109 PACKING RING EA 1 1,575.30

456 A115090380050144 THRUST COLLAR LOCK WASHER EA 1 1,542.13

457 A115090380050007 BALANCE DRUM NUT EA 1 0.01

TEMPORARY IMPREST 48,109.00

TOTAL COST 28,430,313.37

157

UNIT-5 COH COSTING – WORKS :

Sr.

No.Details of Work PO No.

Amount spent in

Unit-5 COH

1Work of the surface painting of Turbine Auxiliaries in

Unit-5, 6 & 7.4500045011 104,110.00

2

Provision of work assistance for CEP strainer / filter

cleaning and turbine side routine miscellaneous

works in Unit-5, 6 & 7.

4500046230 11,129.00

3

Work of cleaning coolers of various auxiliaries of

Unit-5, 6 & 7 during Unit Overhauling, outages or as

& when required.

4500057747 78,652.00

4

Work of Condenser Hot well Inspection, Condenser

Tube Leakage Attending & CEP Suction Strainer

Cleaning as & when required or during outages of

Unit-5, 6 & 7.

4500050968 10,496.00

5

Work of HP Welding of Valves & Pipelines during

routine maintenance, short shutdown & overhaul of

Unit-5, 6 & 7.

4500050531 4,400.00

6 Work of Replacement of Fuller’s Earth, Bucket

Strainer Cleaning & Superfine Filter

4500056607 12,023.00

158

Cleaning/Replacement in FRF system as & when

required or during outages of Unit-5, 6 &7.

7Work of Servicing/Overhauling of Various Pumps

Unit-5, 6 & 7 on as & when required basis.4500060249 -

8Work of replacement of High Pressure Valves in U-

5, 6 & 7.4500057930 -

9Work of repairing of BFP, CEP & FRF strainers at

Unit-5, 6 & 7.4500059534 157,940.00

10Work of fitting cathodic elements in condenser

during AOH/COH Overhaul Unit-6.4500062431 217,550.00

11

Work of Machining of Turbine Fitted Keys, HPBP

valve Stem , hydrogen Seal Brg & Reconditioning of

Recirculation valve of BFP of U # 5, 6 & 7 on as &

when required basis.

4500061735 672,198.00

12Work of inspection and servicing of ACW valves

during Capital Overhauling of Unit-5.4500062874 350,719.00

13

Work of internal inspection & repairs of Deaerator,

FST and HP/LP heater & Oil Tank Cleaning during

COH Unit-5.

4500065165 170,107.00

14

Work of Machining of TG Set Bearing Oil Catchers

& Machining & matching of stellited bush of Control

Valves as per dimensions during overhauls of U-5,

6 & 7.

4500050958 197,636.00

15Work of cleaning / revisioning of MS / HRH strainers

during Capital overhaul of Unit-5.4500062260 1,923,124.00

16

Work of spray insulation of HP / IP turbine module,

connected piping, HP / IP / LPBP stop and control

valves during Capital Overhaul of U-5

4500062823 1,250,366.00

17 Work of cleaning of GTR coolers with De-scaling

agent Silico-6 during respective overhaul of Unit-5, 4500063667 616,815.00

159

6 & 7

18

Work of Overhauling of HP/IP/LP Turbine,

Generator, Exciter& Associated Works during

Capital Overhaul of Unit-5.

4500062595 27,474,447.00

19

Work of inspection and servicing of Steam & Feed

line valves during Capital Overhauling of Unit-5 and

as & when required during shut down of Unit-5, 6 &

7.

4500062886 1,941,399.00

20

Work of Cleaning of Condenser Tubes by High

pressure water jetting followed by bullet shot

cleaning of Main Condenser Unit-5 during Overhaul.

4500063652 576,910.00

21Work of Machining of TG Set Bearing Oil Catchers

& as per dimensions during Overhauls of U-5, 6 & 7.4500062876 183,171.00

22Work of complete overhauling of TDBFP turbines

Unit-5, 6 & 74500064237 977,012.00

23Work of Cleaning of Condenser tubes by high

pressure Hydro-jetting at Unit-6 during COH4500061659 65,664.00

24Work of in-situ machining repair & reconditioning of

HP Control Valves of Unit-5.4500066156 1,011,608.00

25

Work of carrying out Overhauling & various

miscellaneous inspections & replacements in

Condensate Extraction Pump in Unit-5, 6 & 7 on as

& when required basis.

4500056401 332,050.00

26

Work of cleaning of Control Fluid Tank &

Overhauling, Preventive Maintainance of Control

Fluid Pumps in Unit-5, 6 & 7.

4500041950 -

27

Work of thermal insulation of heat exchangers,

turbine pipings, valves etc. of turbine house U-5, 6

& 7.

4500066293 500,000.00

38,839,526.00

160

ODP-II (AHP) :

SN

WORK

AUXILLARY NATURE OF WORK AGENCY/GROUP Unit QTY RATE Amount

1 Raw water tank cleaning Tank cleaning workM/S Babu

EnterprisesEA 1 2704.19 2704.19

2 5 A,B,C sumpSump cleaning

work

M/S Babu

EnterprisesEA 3 4924.98 14774.94

3Raw water Line A & B –

500NB B/FServicing M/s Aarti EA 2 10171.4 20342.7

4 Tank inlet- 350NB B/F Servicing M/s Aarti EA 1 9595.95 9595.95

5 Tank inlet- 500NB B/F Servicing M/s Aarti EA 2 10171.4 20342.7

161

6HP R-C VALVE Plug valve

250NBServicing M/s Aarti EA 2 4970.7 9941.4

7 Sump selection valve

Fly ash sump

selection v/v

servicingM/s Dwiwedi

EA 3 66717.8200153.3

7

Bottom ash sump

selection v/v

servicing

EA 3 11424.8 34274.31

8Sump Make up main

isolation Valve

Servicing/

ReplacementM/s Aarti EA 2 9595.95 19191.9

9 HPAWP-1

Suction valve

servicing

M/s Aarti

EA 1 9595.95 9595.95

Discharge valve

servicingEA 1 9596.95 9596.95

NRV servicing EA 1 9597.95 9597.95

1

0HPAWP-2

Suction valve

servicing

M/s Aarti

EA 1 9595.95 9595.95

Discharge valve

servicingEA 1 9596.95 9596.95


Strainer cleaningdeparmental

workEA 1

1

1

HPAWP-3 Suction valve

servicing

M/s Aarti EA 1 9595.95 9595.95

162

Discharge valve

servicingEA 1 9596.95 9596.95

NRV servicingEA 1 9597.95 9597.95


workEA 1

1

2LPAWP-1

Suction valve

servicing

M/s Aarti

EA 1 4970.7 4970.7

Discharge valve

servicingEA 1 4971.7 4971.7



workEA 1

1

3LPAWP-2

Suction valve

servicingM/s Aarti EA 1 4970.7 4970.7

Discharge valve

servicingM/s Aarti EA 1 4971.7 4971.7

NRV servicing M/s Aarti EA 1 4972.7 4972.7


workEA 1

1

4HPSWP-1

Suction valve

servicing

deparmental

workEA 1 ------ ------

Discharge valve

servicing

deparmental

workEA 1 ------ ------

NRV servicingdeparmental

workEA 1 ------ ------

1

5

HPSWP-2 Suction valve

servicing

deparmental

work

EA 1 ------ ------

163

Discharge valve

servicing

deparmental

workEA 1 ------ ------


workEA 1 ------ ------

1

6LPSWP-1

Suction valve

servicing

deparmental

workEA 1 ------ ------

Discharge valve

servicing

deparmental

workEA 1 ------ ------


workEA 1 ------ ------

1

7LPSWP-2

Suction valve

servicing

deparmental

workEA 1 ------ ------

Discharge valve

servicing

deparmental

workEA 1 ------ ------


workEA 1 ------ ------

1

8

Bottom ash & fly ash sump

strengthning work &Grating

replacement work

Bottom ash & fly

ash sumpM/s Dwiwedi T 3 11195.1 33585.3

1

9

Flushing line header ,

flushing line, Seal water

header, seal water line

replacement.

Flushing line heade

& Nozzle replacedM/s Adore

M 20 587.33 11746.6

80 473.57 37885.6

30 473.57 14207.1

2

0

Fly ash strench strainer &

support fabrication work

Sump grill &

support

replacement

M/s Dwiwedi T 4.5 11195.1 50377.95

2

1Painting Work various paining

workM/s Dwiwedi Sq.

mtr

463.9

6

231 107173.8

4

164

2

2

LPAWP Header line

modification

LPAWP Header line

modificationM/s Adore M 60 587.33 35239.8

2

3

HPAWP Header line

replacement work

HPAWP Header

line replacement

work

M/s Adore M 46 587.33 27017.18

SUPPLY

E CODE SPARE Unit QTY. RATE AMOUNT

A028140010010021 NON METALLIC ROUND- ID 400 OD 600 THK 5M EA 8 436.52 3492.13



A036010010050001 LUBRCNT GRS EQ&MC/NRY IOC SERVO GEM 03 KG 2 187.68 375.36

A027100010080001 GSKTMTRL 1000 MM X 2000 MM KG 5 218.73 1093.64




A028140010010022 STYLE -20N/M ROUND-ID 300 OD600 TH5MM EA 13 450.21 5852.79


A075270150010001 VLV PLUG 150CI FG200 600NB COMP ISOLATION VALVE EA 3 298390.78 895172.34


A028140010010022 STYLE -20N/M ROUND-ID 300 OD600 EA 12 450.21 5402.57

165

TH5MM

A028140010010051 METALLIC ROUND-ID300 OD 530THK 5.0 MM EA 6 355.00 2130.00

A028140010010036 NON METALLIC ROUND- ID 350 OD 530 THK 3. EA 20 183.76 3675.23



A027050010050005 GSKTMTRL 16 MM SQ IN PACK OF 5 KG KG 3 374.63 1123.90








A027050010050005 GSKTMTRL 16 MM SQ IN PACK OF 5 KG KG 2 374.63 749.26






166









A107040010030014MS ISMC CHANNEL SIZE 150 X 75 MM TO 0.600 39204.03023 23522.42

A107030010040005 BEAM MS ISMB 200 X100 MM TO 1.000 39793 39793.00

A111010020040003 MSERW/PIPE/IS-3589/SIZE-200X219.1X7.9 MM M 20 1857.02 37140.42

A111010020030011MSERW/PIPE/IS-1239/SIZE-80X89.5X4.85 MM M 80 455.6625 36453.00

A111010020030001MSERW/PIPE/IS-1239/SIZE-100X115X5.4 MM M 30 670.50 20115.00

A027010010240007 GSKT&PCK JNT SHT1525 X 1650 MM TH 3.0 MM EA 7 253.60 1775.19

A027010010220007 JOINTINGSHET OIL NONMET1525X1650MMTH3MM KG 10 265.94 2659.42

A107030010040005 BEAM MS ISMB 200 X100 MM TO 1.540 39793 61281.22

A107040010030014MS ISMC CHANNEL SIZE 150 X 75 MM TO 1.000 39204.03023 39204.03




167


Total 1547656.10

ODP-II WHP:

SUPPLY EXPENDITURES

MATERIAL SAP CODE QTY. RATE AMOUNT

1

U#5 CT 5A/5B RISER

VALVE REPLACEMENT

WORK (600NB

BUTTERFLY)

STYEL 54 SUPER

NON METAL

A027010010240008 115 212.82 24474.30

FASTNER M 20 X

120

A114010090020124 100 88.38 8838.00

GASKET 1000MM X

2000MM

A027070010070001 105 89.44 9391.20

JOINT SHEET NON

METAL

A027010010190005 34 110.41 3753.94

BUTTERFLY VALVE

600NB

A075030020110001 10 125657.6

0

1256576.00

2

CT 5A/5B HOT WATER

PIPE REPLACEMENT

WORK 150 NB & 200 NB

ASBESTOS

CEMENT PIPE

150NB

A083050010010003 109 3241.75 353350.75

ASBESTOS

CEMENT PIPE

200NB

A083050010010004 31 4095.63 126964.53

3 U# 5 CT 5A/5B NOZZLE

CLEANING & REPL

WORK

COOLTWR NOZZLE A083050050010002 8000 16.32 130560.00

COOLTWR

MODIFIED NOZZLE

A083050050010001 5000 114.01 570050.00

4 CT FAN 5B/6 & 5B/8

COMPLETE GEAR BOX

REPLACE WORK

GB GRV VH

M1700R15-1 I/P

BEVEL & PINION

A097080090010002 2 659886.5

9

1319773.18

168

GB GRV VH

M1700R15-1 CSNG

UPR & LWR SET

A097080090010003 2 268482.7

0

536965.40

GB GRV VH

M1700R15-1

OUTPUT WHEEL

A097080090010004 2 711181.2

0

1422362.40

5

CT FAN 5A/5 GEAR

BOX OVERHAUL WORK

- RADICON ( BRG

REPL )

I/P FRONT( WORM

SHAFT)

A072020060010104 2 17263.50 34527.00

I/P BACK (WORM

SHAF)

A072020020050054 1 8524.00 8524.00

O/P shaft Top &

BOTTOM

(WORM WHEEL)

A072020060010110 2 26637.30 53274.60

6

CT FAN 5B/1 GEAR

BOX OVERHAUL WORK

- PREMIUM ( BRG

REPL )

TAPER ROLLER

SINGLE ROW BRG

32321 J2

A072020060010207 2 23116.87 46233.74

BRG MET TAPROL

SR 32319 J2

A072020060010060 2 16022.00 32044.00

GEAR BOX OIL SP-

320

A036020100010013 560 167.52 93811.20

COUPLING BUSH A119010010010122 59 524.89 30968.51

7 U#5 ACW/CCW SUMP

SUCTION STRAINER

REPAIRING WORK

BAR MS ROUND 10

MM

A107020070010003 0.3 36954.27 11086.28

8 CT FAN 5A/1 & 5B/1

MOTOR FOUNDATION

FRAME REPLACEMENT

CHANNEL MS ISMC

100X50

A107040010030002 1 42464.58 42464.58

9 U#5 ACW RETURN LINE

SEPARATION WORK AT

5A & 5B TOWER

GATE VALVE 150NB A075170080070001 30 16445.00 493350.00

MSERW PIPE AC04309001004001 90 12263.00 1103670.00

169

600NBX2000MM 0

MSERW PIPE 400NB A111010020040011 60 4800.51 288030.60

MSERW PIPE 350NB A111010020040009 280 4177.02 1169565.60

MSERW PIPE

300NBX323.9X9.5M

M

A111010020040007 100 3525.93 352593.00

MSERW PIPE 300NB A111010020040006 100 3094.77 309477.00

MSERW PIPE 150NB A111010020040001 210 1813.88 380914.80

CHANNEL MS ISMC

150 X 75

A107040010030014 1 39205.94 39205.94

MS PLATE 25MM A107060010020012 0.2 40000.00 8000.00

Paint 150000.00

TOTAL SUPPLY 10410800.55

WORK ITEM TOTAL

1 U#5 CT 5A/5B RISER VALVE REPLACEMENT WORK (600NB BUTTERFLY) 37020

2 U# 5 CT POND CLEANING WORK & U#5 ACW/CCW SUMP CLEANING WORK & U#5 ACW/CCW SUMP SUCTION STRAINER REPAIRING WORK 592204

3 U# 5 CT 5A/5B HOT WATER BASIN CLEANING WORK 242000

170

4 CT 5A/5B SPLASH BAR CLEANING & REMOVAL BY SCRAPPING 405,466

5 U#5 CCW/ACW PUMP HOUSE VARIOUS VALVE SERVICING WORK 200000

6 U#5 ACW RETURN LINE SEPARATION WORK & anchoring of pipes 1600000

7 CCW BFV servicing by VAG 810000

TOTAL WORKS 3886690

INSTRUMENTATION & CONTROL - II :

WORKS

SN

RP No. P.O.No. Vendor Name Description Amount B. Code

1 T-766 450005927 Shubham Enterprises,

Servicing of Power cylinder in bottom ash

Rs. 525,271

CHN/WP/OH/E07

171

5 Chandrapur system, burner tilt, PA general gate

2 T-1954 4500063621

Dharma B. Chanekar, Chandrapur

Work contract for cleaning and painting of JB, TRB/ TRT Panel,Instrument racks & impulse Line flushing during AOH/ COH of unit-5.

Rs. 569,759

CHN/WP/OH/E07

3 T-1956 4500063752

Panchajanya Services, Kolkata

Work contract for modification in coal mill DP measurement system of unit-5

Rs. 433,200

CHN/WP/OH/E07

4 T-2092 4500063781


Work of servicing and modification of complete Gland Drain Tank levelcontrol system of Unit 5

Rs. 68,700

CHN/WP/OH/E07

5 T-1938 4500065339


Work of servicing and calibration of pneumatic control valves, dampers and various transmitters during AOH/COH of Unit-5.

Rs. 720,339

CHN/WP/OH/E07

6 T-1955 4500065281 J. P. Nagdeve

Work contract for servicing of Igniter, Flame Scanners and SADC during AOH, COH of unit-5.

Rs. 128,741

CHN/WP/OH/E07

7 T-1957 4500065546

PRIYA ENGINEERING WORKS

Work contract for servicing of HP Bypass system instruments with FOD during 500MW U-5, AOH / COH.

Rs. 247,303

CHN/WP/OH/E07

8 T-331 4500044300


Work contract for servicing of solenoid valves

Rs. 67,415

CHN/WP/OH/E07

9 T-741 4500048613


Work contract for servicing of solenoid valves

Rs. 74,050

CHN/WP/OH/E07

Total Rs. 2,834,778

SUPPLY :S/N Material Material Description

Quantity

Amount in LC Text

1 A11419006001000 FASTNRS M 16 -3 -207.82 UNIT # 5

172

4

2A114030080040017 FASTNRS M 5 -2 -183.01 UNIT # 5

3A114030080040004 FASTNRS M 16 -4 -328.83 UNIT # 5

4A114010090010196 FASTNRS M 6 X 30 -1 -94.11 UNIT # 5

5A114010090010181 FASTNRS M 5 X 30 -1 -47.00 UNIT # 5

6A114010090010043 FASTNRS M 14 X 65 -2 -167.20 UNIT # 5

7A114010050010015 FASTNRS M 12 X 65 -1 -8.57 UNIT # 5

8A114010050010006 FASTNRS M 10 X 50 -1 -7.88 UNIT # 5

9A111120270010009 REDUCER MALE 1 / 4 TUBE X 3 / 8 -7 -1176.23 UNIT # 5

10A111120260010007 MALE X MALE 1 / 4 TUBE X 3 / 16 TUBE -4 -320.00 UNIT # 5

11A111120200020027 CONECTR FEMALE 1 / 4" X 3 / 8" BSP -1 -241.77 UNIT # 5

12A111120200010008 CONNECTOR MALE 1 / 4 TUBE X 3 / 8 NPT -3 -504.10 UNIT # 5






18A111120150020014 TEE BRANCH MALE 1 / 4 TUBE X 1 / 4 BSP -2 -551.41 UNIT # 5

19A111030130020035 MS CONNECTOR 1/2" BSP (M) X 1/2" NPT (M) -1 -24.48 UNIT # 5






25 A11103013002003 MS CONNECTOR 1/4" BSP (M) X 1/2" NPT (M) -1 -24.48 UNIT # 5

173

3



28A111030130020018 PIP FT FE CNCTR 4 / 8" X 1 / 4" -3 -68.18 UNIT # 5

29A111030130020007 MS CONECTR TUBEOD1/4"X1/4"NPT(M) -1 -13.26 UNIT # 5

30A111030030030002 MS REDUCER 1 / 4" BSP (M) X 3 / 8" BSP ( -54 -1350.00 UNIT # 5

31A111020010010006 PIPE SCH 10 FLEXIBLE OD 8 MM X ID 6 MM -1.500 -134.14 UNIT # 5

32A110060130030004 MS 80 NB FLANGE DUMMY -2 -507.96 UNIT # 5

33A110060130030004 MS 80 NB FLANGE DUMMY -2 -507.96 UNIT # 5

34A104030400010002 LUG CU I/L CNCTR WITH SLV 2.5SQMM -10 -30.62 UNIT # 5



37A104030390010002 LUGS CU FL WITH SLV 2.5SQMM -50 -156.16 UNIT # 5

38A104030390010001 LUGS CU FL WITH SLV 1.5SQMM -10 -30.09 UNIT # 5

39A104030380010002 LUG CU PIN TYPE WITH SLV 2.5MM2 -25 -36.33 W T PLANT

40A104030380010002 LUG CU PIN TYPE WITH SLV 2.5MM2 -60 -87.20 UNIT # 5


42A104030380010001 LUG CU PIN TYPE WITH SLV 1.5MM2 -25 -65.18 W T PLANT


44A104030370020002 LUGS CU U-TYPE WITH SLV 1.5SQMM -50 -68.70 UNIT # 5

45A104030060030001 CU RECT FRK SLDRLES 2.5MMSQ LUG-7928 -10 -18.15 UNIT # 5




49 A10403006003000 CU RECT FRK SLDRLES 2.5MMSQ LUG-7928 -10 -18.15 UNIT # 5

174

1

50A104030060030001 CU RECT FRK SLDRLES 2.5MMSQ LUG-7928 -25 -45.37 W T PLANT






56A103130040010002 TOP PIN PVC PLUG TOP V240 5 AMP -4 -101.87 UNIT # 5

57A103070140010009 LMP FT LAMP IND V 30 A 50 MA -31 -62.00 UNIT # 5

58A103070140010006 LMP FT LAMP IND TYPE V 30, A -5 -50.00 UNIT # 5

59A102240010010006 300 (L) X 315 (B) X 170 (H) MM WITH HING -1 -3473.08 UNIT # 5

60A102230020020017 LLGS,CEE EM45 SERIES WITH NORMAL ROLLER -1 -265.00 UNIT # 5

61A102230020010001 JAI BALAJI 2 NO + 2 NC TYPE-JB2700DPDT -1 -3120.00 UNIT # 5

62A102230010020001 INSTRFLD LMTSWT BCH 1NO+1NC TYPE: LTPR -1 -771.43 UNIT # 5

63A102180030020003 PR SWITCH-DIFF SWITZER 0.2TO 4 BAR -1 -8200.00 UNIT # 5

64A102180030010031 INST FLD PR SW DIF 5-60 PSI MP55 -3 -8070.00 UNIT # 5

65A102180010020006 SWITCH GEORGIN RANGE - 0 TO 5000 PA -1 -111384.42 UNIT # 5

66A102160120010016 INSTRFLD TEMP THERMOWEL HP IL: 250 MM -1 -0.01 UNIT # 5

67A102160090010012 TC-MI SIMPLEX K-TYPE L 4 METER OD 3 MM -4 -29281.20 UNIT # 5

68A102160080010020 K-TYPE NIPPLE FOR IP TURBINE T / C -4 -2066.67 UNIT # 5

69A102160070020002 TC-MI WELDING PAD OD 6 MM T / C -1 -272.34 UNIT # 5

70A102160060020221 TC-DUPLEX, K-TYPE, IL 300 MM, EL 100 MM -1 -15403.86 UNIT # 5

71A102160060020180 INST FLD TMP SNSR HP OUTER CASING -5 -30550.00 UNIT # 5

72A102160060020105 K-TYPE L 840 MM, OD 8 MM ELEMENT -1 -0.01 UNIT # 5

73 A10216006002005 K-TYPE IL 700 MM, EL 140 MM ASSY -1 -5507.44 UNIT # 5

175

1

74A102160060020025 K-TYPE IL 150 MM, EL 90 MM ASSY -1 -0.01 UNIT # 5

75A102160010010351 RTD-DUP, PT-100, L13 MM, OD3MM, 2WIRE -4 -3366.00 UNIT # 5

76A102160010010350 RTD L 70 MM, OD 6.5 MM, 3 WIRE ELEMENT -1 -1535.54 UNIT # 5

77A102160010010299 INST FLD TMP SNSR OD8MM,L400MM,3WIRE -1 -1312.74 UNIT # 5






83A102160010010267 PT100 L 100 MM, OD 8 MM, 3 WIRE ELEMENT -1 -982.26 UNIT # 5





88A102150060020029 0 TO 120 DEG C, DIA-6 MM, STEM L 300 MM -1 -2236.86 UNIT # 5

89A102150020020204 0 TO 250 DEG C, BULB DIA-8 MM, CAP L 5.0 -1 -2236.86 UNIT # 5



92A10214049001000

2 REPAIR KIT ASCO P / N A302 322 -1 -3540 UNIT # 5

93A10214049001000

1 COMPLETE SOLENOID VALVE ASSY ASCO P / N -1 -4446.36 UNIT # 5

94A10214047001000

2 REPAIR KIT ASCO P / N A316 753V -1 -6239.64 UNIT # 5

95A10214043001000

2 REPAIR KIT ASCO P / N A302 725 MO -1 -816 UNIT # 5

96A10214043001000

2 REPAIR KIT ASCO P / N A302 725 MO -1 -816 UNIT # 597 A10214043001000 REPAIR KIT ASCO P / N A302 725 MO -1 -816 UNIT # 5

176

2

98A10214043001000

2 REPAIR KIT ASCO P / N A302 725 MO -1 -816 UNIT # 5

99A102130050060078 INST FLD PR GAUG 0-2.5KG/CM2,CON1/2"BSP -1 -845.42 UNIT # 5

100

A102130050060078 INST FLD PR GAUG 0-2.5KG/CM2,CON1/2"BSP -1 -845.42 UNIT # 5

101

A102130050060016 0-25 KG/CM2, CON 1 / 2" BSP -3 -2274.01 UNIT # 5

102

A102130050030098 PR GAUGE DIAL 100 MM 0-2.5 KG / CM2 -2 -1397.46 UNIT # 5

103

A102130050020060 0 TO 6 KG/CM2, CON 1 / 2" BSP -1 -698.73 UNIT # 5

104


105


106


107


108


109


110


111


112


113


114


115

A102120020050002 ILK MODEL HTPWO / BP -1 -0.01 UNIT # 5

116

A102080070030003 ROTAMETER 0 TO 45 LPH FOR SWAS -2 -6485.16 UNIT # 5

117

A102080070030003 ROTAMETER 0 TO 45 LPH FOR SWAS -1 -3242.58 UNIT # 5

118

A102070010020002 ELECTRONIC PFTRANSM. MODEL EPT002, I / P -2 -40166.28 UNIT # 5

119

A102070010020002 ELECTRONIC PFTRANSM. MODEL EPT002, I / P -1 -20083.14 UNIT # 5

120

A102060010010001 I/P 4 TO 20 MA, O/P 0.2 TO 1.0 KG / SQ.C -1 -14040.50 UNIT # 5

12 A10206001001000 I/P 4 TO 20 MA, O/P 0.2 TO 1.0 KG / SQ.C -1 -14040.50 UNIT # 5

177

1 1122


123


124

A102050010060017 FORBE MARSHALL DIGITAL INDICATOR ASSY -1 -4584.29 UNIT # 5

125

A102020040050001 FORBES MARSHAL CONDUCTIVITY METER -1 -34382.16 UNIT # 5

126

A100120010010019 I&C TRBVSRYSENSOR PROBE ASSY -1 -0.01 UNIT # 5

127

A100090040020059 TRIP INDICATION LAMP IDENT CODE3SB12 91 -5 -765.00 UNIT # 5

128

A100070040010004 PRESSURE FILTER ELEMENT PN 60 / 00018. -2 -15140.00 UNIT # 5

129

A100070030060015 SET OF PICKINGS OF SERVO VALVE ST-10.65 -1 -19683.96 UNIT # 5

130

A100070030060015 SET OF PICKINGS OF SERVO VALVE ST-10.65 -1 -19683.96 UNIT # 5

131

A100070030060010 SET OF PICKINGS TO SERVO VALVE ST10 4+R6 -1 -6921.93 UNIT # 5

132

A100070030060009 SB FILTER FOR SERVO VALVE ST10-63 / 4 -1 -22172.76 UNIT # 5

133

A100070030060006 SERVO VALVE FIXING BOLT M6 X 130 WITH WA -1 -1131.18 UNIT # 5

134

A100070030050064 FILTER INSERT FOR HC9020 OIL UNIT -4 -47209.19 UNIT # 5

135

A100070030050064 FILTER INSERT FOR HC9020 OIL UNIT -1 -11802.30 UNIT # 5

136

A100070030050008 FILTERS FILTER INSERT BIG HC9600 FUP4H H -2 -35233.69 UNIT # 5

137

A100070030040006 SULZER HOSE O' RING SET -2 -2262.36 UNIT # 5

138

A100070030020005 BL-10 SET OF PACKING CODE 97450240 -1 -2899.12 UNIT # 5

139

A100060080010014

COAL FEEDER CONTROL PANEL TRANSFORMER, O -1 -8000.00 UNIT # 5

140

A100060060020016 PROCESSOR POWER SUPPLY -3 -0.03 UNIT # 5

141

A100060060020016 PROCESSOR POWER SUPPLY -1 -0.01 UNIT # 5

142

A100060060020015 I&C FSSS MODICON MA-0185-100 -1 -0.01 UNIT # 5

143

A100060010050014 I&C FSSS BHEL SPARK ROD TIP-IMPORTED -4 -227430.81 UNIT # 5

144

A100060010050001 ALLAN SCREW FOR IGNITOR 4 MM -2 -36.72 UNIT # 5

14 A10006001005000 ALLAN SCREW FOR IGNITOR 4 MM -4 -73.44 UNIT # 5

178

5 1146

A100060010050001 ALLAN SCREW FOR IGNITOR 4 MM -10 -183.60 UNIT # 5

147

A100060010040015 FSSS HEA ADV/RET ASSY SPARK ROD CLAMPS -4 -913.92 UNIT # 5

148

A100060010040014 AS PER SPEC HEA ADV/RET ASSY SPARK ROD -2 -5672.16 UNIT # 5

149


150


151

A100060010040012 AS PER SPEC HEA ADV/RET ASSY PC SEAL KIT -1 -2688.14 UNIT # 5

152


153


154

A100060010030020 HEAI EXCITER COMPLETE ASSY -2 -62393.76 UNIT # 5

155

A100060010020042 SAFE SCAN II LITTLE FUSE FOR LAMP & METE -5 -472.68 UNIT # 5

156

A100060010020040 SAFE SCAN II FLAT LENS THK 1.5 MM X OD 2 -5 -640.71 UNIT # 5

157

A100060010020040 SAFE SCAN II FLAT LENS THK 1.5 MM X OD 2 -18 -2306.54

SCANNER REPAIR

158

A100060010020039 SAFE SCAN II COLLIMETER LENS & BARREL AS -15 -18054.00

SCANNER REPAIR

159

A100060010020035 SAFE SCAN II FIBRE OPTIC CABLE -16 -49543.68

SCANNER REPAIR

160

A100060010020022 SAFE SCAN II HOUSING ELECTRONIC CARD -18 -132192.00

SCANNER REPAIR

161

A100060010020015 SAFE SCAN II COLLIMATOR TUBE -5 -3069.33

SCANNER REPAIR

162

A100060010020015 SAFE SCAN II COLLIMATOR TUBE -5 -3069.32

SCANNER REPAIR

163

A100060010020005 FLAME SCANNER SAFE SCAN II ALLAN SCREWS -2 -20.00

SCANNER REPAIR

164

A100040010020009 I&C DCS ABBPRO POWER AMPFR AVL-AA -1 -88700.00

SCANNER REPAIR

165

A100030010020009 I&C DAS SIEMEN HARD DISK DRIVE 160GB -1 -3000.00 UNIT # 5

166

A100010020010009 I&C ACS H&B AV-42:PROT&ANLG SIGNL DISTR -1 -0.01 UNIT # 5

167

A098170010010001 HNDTOOL OILCAN FIXSPOUT WESCO 1/2 -1 -1236.24 UNIT # 5

168

A098130020020001 HNDTOOL HKSAW BLAD ALOY 1/2"X12"X18TPI -5 -40.51 UNIT # 5

16 A09813002001000 HNDTOOL HKSAW BLAD HSS 1/2"X12"X24TPI -5 -166.01 UNIT # 5

179

9 4170

A098130020010003 HNDTOOL HKSAW BLAD HSS 1/2"X12"X18TPI -3 -113.49 UNIT # 5

171

A098110010010009 HNDTOOL DRILBIT MET PARALLSHANK 6MM -1 -115.20 UNIT # 5

172

A098050010020002 HNDTOOL FILE FLAT SMOOTH 200MM/8" -1 -663.00 UNIT # 5

173

A098030050010003 HNDTOOL PLIR COMB ELEC 8" -2 -655.20 UNIT # 5

174

A098030050010003 HNDTOOL PLIR COMB ELEC 8" -1 -327.60 UNIT # 5

175

A098020010010074 ELECTRICAL PATTERN TAPARIA PRODUCT -1 -95.68 UNIT # 5

176

A098020010010025

HNDTOOL SCRWDRIVER FLAT ELEC 125MMELECT -1 -77.28 UNIT # 5

177

A098020010010025

HNDTOOL SCRWDRIVER FLAT ELEC 125MMELECT -1 -77.27 UNIT # 5

178

A098010030010003 HNDTOOL SPANNER SINGLEND 300MM/12" -1 -490.12 UNIT # 5

179

A098010030010003 HNDTOOL SPANNER SINGLEND 300MM/12" -1 -490.12 UNIT # 5

180

A095770080010001 VSLOW-BLOW GLASS FUSE 500 VAC FNO-6 TIME -1 -900.00 UNIT # 5

181

A095130040010002 FUSE FUSE, TYPE: HF, CAT NO: SF 90152 -1 -56.00 UNIT # 5

182

A091010090070001 ROT2W2P 16A SWITCH KAYCEE RP125B -1 -520.00 UNIT # 5

183

A085060070120016 ELECTINSU FOR 4.0 SQ.MM WIRE -1 -48.86 UNIT # 5

184

A085060070120014 ELECTINSU FOR 2.5 SQ.MM WIRE -1 -34.68 UNIT # 5

185

A085060070060028 SLEEVE GLASS FIBER VARNISHED 10 SQ MM -1 -12.24 UNIT # 5

186

A078020160070002 CHEM 340 GM SPRAY CAN -2 -367.37 UNIT # 5

187


188


189


190


191


192


19 A07802016007000 CHEM 340 GM SPRAY CAN -1 -183.69 UNIT # 5

180

3 2194


195

A078020160040001 CHEM 1 / 2 LTR TIN PACK -1 -71.82 UNIT # 5

196

A078020160040001 CHEM 1 / 2 LTR TIN PACK -1 -71.82 UNIT # 5

197

A078020160010001 CHEM 340 ML SPRAY CAN -1 -173.75 UNIT # 5

198


199


200


201


202


203


204


205


206


207


208

A078020060030001 CHEM CNTCT-CL KLINIT SPRAY TIN 350 ML -1 -230.39 UNIT # 5

209


210


211


212


213


214


215


216


21 A07802006003000 CHEM CNTCT-CL KLINIT SPRAY TIN 350 ML -1 -230.39 UNIT # 5

181

7 1218


219


220


221

A078020030010008 CHEM COLIN BOTTLE -1 -57.85 UNIT # 5

222

A078020030010008 CHEM COLIN BOTTLE -2 -115.69 UNIT # 5

223

A078010010080002 CHEM ADH COMP GP FEVICOL 100ML -4 -103.54 UNIT # 5

224

A078010010080002 CHEM ADH COMP GP FEVICOL 100ML -5 -129.43 UNIT # 5

225

A078010010070004 CHEM ADH COMP GSKT SPEB-7 500ML TIN -2 -211.17 UNIT # 5

226

A078010010050015 SEALENT ANABOND 666 100 GM PKT -1 -95.86 UNIT # 5

227

A078010010050015 SEALENT ANABOND 666 100 GM PKT -1 -95.86 UNIT # 5

228

A078010010050012

CHEM ADH COMP SEAL INDIAN HDSHELLAC 60ML -3 -39.00 UNIT # 5

229

A078010010020017 CHEM ADH COMP STEEL M SEAL-FASTCURE 1KG -0.250 -53.87 UNIT # 5

230

A078010010020017 CHEM ADH COMP STEEL M SEAL-FASTCURE 1KG -3 -646.43 UNIT # 5

231


232


233


234


235

A078010010020017 CHEM ADH COMP STEEL M SEAL-FASTCURE 1KG -0.250 -53.87 W T PLANT

236


237


238


239


240

A077110010020002 CBLMTL CONCTR BKLT 12WAY 2.5 SQMM -8 -530.00 UNIT # 5

24 A07711001002000 CBLMTL CONCTR BKLT 12WAY 1.5 SQMM -9 -321.30 UNIT # 5

182

1 1242

A077040030010001 CABLE CBLE TIE NYLON 2 MM TH TIE 2.5 MM -35 -89.25 UNIT # 5

243

A051030780010002 POW CYL SEAL KIT -1 -1122.00 UNIT # 5

244

A051030250010008 PWR CYL BR330MMXSTR 600MM SEAL KIT -1 -1530.00 UNIT # 5

245

A051030250010008 PWR CYL BR330MMXSTR 600MM SEAL KIT -2 -3060.00 UNIT # 5

246

A051030020010004 PWR CYL 1ACT,ON-OFF SHAFT SL -3 -198.90 UNIT # 5

247

A051020110010006 PWR CYL PISTN ROD,DISC,LCK,CHCKNUT -1 -32211.83 UNIT # 5

248

A051020110010004 MAKE WIPRO SLEEVE -1 -39688.20 UNIT # 5

249

A050020020110001 WITHOUT SLEEVE 8 MM DIA TH 1.0 MM -2 -120.00 UNIT # 5

250

A048010040380001 PAINT STANDARD WHITE 1 LITRE PACK -1 -279.48 UNIT # 5

251

A048010040030003 PAINT STANDARD LIGHT GREY 1 LITRE PACK -1 -279.48 UNIT # 5

252

A048010040010003 PAINT STANDARD BLACK 1 LITRE PACK -2 -546.72 UNIT # 5

253

A047060010010001 SQUARE NEOPRENE 7 MM IN CONTINEOUS L -50 -7650.00 UNIT # 5

254

A039080010010004 DIGITL MLTIMTR STD MOTWANE DM 6K3 -1 -6538.20 UNIT # 5

255

A039080010010001 DIGITL MLTIMTR STD MOTWANE LEAD ACCSRS -1 -213.74 UNIT # 5

256

A039080010010001 DIGITL MLTIMTR STD MOTWANE LEAD ACCSRS -1 -213.74 UNIT # 5

257

A036020160020001 LUBRCNT OIL TURB IOC SERVO PRIME: 32 -5 -895.50 UNIT # 5

258

A036020130010002 LUBRCNT OIL SP HYDR IOC SERVO SY HLP:68 -50 -7211.35 UNIT # 5

259

A036020090030006 LUBRCNT OIL CV HYDR IOC SERVO CONVAL-46 -60 -9654.24 UNIT # 5

260

A033030010360012 INSTPNL INDCTRANLG1SCL O/P0-199.50A -2 -0.02 UNIT # 5

261

A033020060060018 INSTPNL DESK PUSH BUTTONS FOR CPU -1 -0.01 UNIT # 5

262

A033020040090027 LED INDICATOR 24 VAC MINIATURE LAMP -10 -1224.00 UNIT # 5

263


264


26 A03201005002000 HOSE FLX SSCORRU 1/4"BSP(F),L 0.8 M -2 -580.00 UNIT # 5

183

5 2266

A032010050020002 HOSE FLX SSCORRU 1/4"BSP(F),L 0.8 M -3 -870.00 UNIT # 5

267

A032010050020002 HOSE FLX SSCORRU 1/4"BSP(F),L 0.8 M -2 -580.00 UNIT # 5

268

A032010020010039 SS BRAIDED LOW PR RUBBER HOSE -1 -42.84 UNIT # 5

269


270


271


272


273


274


275


276


277


278


279


280


281


282


283


284


285


286

A032010020010007 HOSE RUBBER SSBRD 3/8"X3/8" BSP,L500MM -4 -251.33 UNIT # 5

287

A032010020010007 HOSE RUBBER SSBRD 3/8"X3/8" BSP,L500MM -2 -125.67 UNIT # 5

288

A029120020020002 ELECT INSUL TAPE STEEL GRIP BLACK -BHOR -1 -9.38 UNIT # 5

28 A02912002002000 ELECT INSUL TAPE STEEL GRIP BLACK -BHOR -1 -9.38 UNIT # 5

184

9 2290


291


292


293


294


295


296


297


298


299


300


301


302

A029120020020002 ELECT INSUL TAPE STEEL GRIP BLACK -BHOR -1 -9.38 W T PLANT

303


304


305


306


307


308


309


310


311


312

A029100030010006

HARDWR TORCH CELL PAPERSEAL NORMAL1,5VCE -3 -30.45 UNIT # 5

31 A02910003001000 HARDWR TORCH CELL PAPERSEAL -3 -30.45 UNIT # 5

185

3 6 NORMAL1,5VCE314

A029100030010006


315

A029100030010006


316

A029100030010006


317

A029100010010005 TORCH EVEREADY DIGILED -2 -306.00 UNIT # 5

318

A029070030020005 POLYTHENE BAG THK 0.2 MM 12 X 18 INCH -6 -1158.95 UNIT # 5

319

A029070030020004 HARDWR POLY BAG 0.2MM SIZE24X24 INCH -20 -3266.99 UNIT # 5

320

A029070030020001 HARDWR POLY BAG 0.2MM 6X9 INCH -3 -502.90 UNIT # 5

321

A029070030010003 HARDWR POLY BAG 0.1MM 12X18 INCH -5 -712.55 UNIT # 5

322

A029070030010001 HARDWR POLY BAG 0.1MM 6X9 INCH -8.500 -1164.20 UNIT # 5

323

A029070010010002 HARDWR POLY PAPER 0.2MM 1.5 M WIDE -2 -398.80 UNIT # 5

324

A029070010010002 HARDWR POLY PAPER 0.2MM 1.5 M WIDE -5 -996.99 UNIT # 5

325

A027130070010003 PTFE TAPE ROLL 25 MM W 12 M -1 -33.85 UNIT # 5

326


327


328


329


330


331


332


333


334


335


336

A027130070010001 PTFE TAPE ROLL 12.5 MM W 12 M -1 -17.32 UNIT # 5

33 A02713007001000 PTFE TAPE ROLL 12.5 MM W 12 M -1 -17.32 UNIT # 5

186

7 1338


339


340


341


342


343


344


345


346


347

A027130070010001 PTFE TAPE ROLL 12.5 MM W 12 M -1 -17.32 W T PLANT

348


349


350


351


352


353


354


355


356


357


358


359


360


36 A02713007001000 PTFE TAPE ROLL 12.5 MM W 12 M -1 -17.32 UNIT # 5

187

1 1362


363

A027010010190004 STYLE 20 STEAM NON METALLIC 1525X1650MM -17 -1707.99 UNIT # 5

364

A023040010040011

COMPLETE REGULATOR HIGH FLOW WITH PRESSU -1 -920 UNIT # 5

365

A023040010040011


366

A023040010040011


367

A023040010040011


368

A023040010030001

COMPLETE REGULATOR WITH PRESSURE GAUGE 1 -6 -9487.74 UNIT # 5

369

A019010010070038 CNTCTR&STRTR 3TH 30-22-0AF0 -1 -0.01 UNIT # 5

370

A016040020020003 CBLINS CMPN TC KTYPE PVC-UARMR PR2 -4 -440 UNIT # 5

371

A016010020030001 CBLINS 1.1SCR CUMLTUAR CR4 1.50SQMM -3 -302.94 UNIT # 5

372

A014040020210001 CORE 1 1.5 SQMM -20 -387.6 UNIT # 5

373

A003020090140001 ACTUATOR PNEUMATIC ILP M-SPA1M SEAL KIT -1 -1530 UNIT # 5

Total 1446401.00

TESTING - II :

SUPPLY

SR. NO.

MATERIAL DESCRIPTION AMOUNT

1. Relays 1,53,799

2. Ammeter / Annunciators 26,246

188

3. Capacitor / Fuses 32,972

4. Push buttons/ LEDs 17,332

5. Actuator spares 3,13,763

6. Consumables 3,000

Total Amount in Rs. 5,47,112

WORKS

SR. NO.

Order details AMOUNT

1. Work of servicing of actuator limit switch assembly of motorised valves, gates & dampers

CSTPS/4500060623, Dtd. 23.09.15

1,97,110

2. Work contract for testing of ABB/EE make switchgear protection relays

CSTPS/4500061878, Dtd. 26.09.15

6,00,000

Total Amount in Rs. 7,97,110

Total R&M expenditure during Unit#5 COH in Rs. = Rs. 5,47,112 + Rs. 7,97,110

= Rs. 13,44,222/-

= Rs. 13.44 lakhs

189

Date post:	12-Jul-2016
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U#U COH_16_FINAL_10.03.2016

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