98676767

NTPC LTD.
TALCHER SUPER THERMAL POWER PROJECT

Recommissioning Report Of
UNIT - 6
Annual Overhauling
(From 23-05-08 to 18-06-08) 27 Days
TSTPP , STAGE – II UNITS

(4X500 MW)
Compiled By
Recommissioning Group .
Operation Department
Date 22/11/2008
NTPC /TSTPS Annual Overhauling Report U – 6
23rd May’08 to 18rd June’08
INDEX
SL.
SUBJECT PAGE NO
NO.
1. Introduction 5 -7
2. Overhauling Team 9
3. History of Unit - 3 & Stage – II Units 11
4. Recommissioning Milestone Activities . 13-14
Different Protocols & check lists used on Boiler /TG /Elect
5. 16-17
systems
6. Modifications & Improvements during Overhauling 19-21
7. Major Problems EXPERIENCED during Recommissioning. 23
8. Surprises & Learning’s 25
9. New methods & Procedures adopted 27
10. SUGGESTIONS FOR IMPROVEMENT. 29
11. Important EVENTS. 31-35
12. Joint Inspections Carried Out (BLR /TG/ELECT) 37-39
13. Joint Testing carried (BLR /TG/ELECT) 41
14. P&I check DETAILS. 43
15. Elect Switchgear & Battery Chargers OVERHAULING DETAILS 44-48
16. Major Pending JOBS after overhauling. 50
17. Major activities details
a. TG Set barring gear stop activity 52-53
b. H2 purging out before start of overhauling 54
c. H2 Filling after overhauling 55
d. Generator Air tightness test 56
e. Condenser Flood Test 57
f. Boiler Hydrotest 58-59
g. MOT Draining & refilling 60
h. Boiler Safety Valve Floating Parameters 61
i. Furnace Pressurization test 62
18. Others
• BOILER COOLING DOWN PARAMETERS . 64-66
• TURBINE COOLING DOWN PARAMETERS FROM
67-69
BARRING GEAR TO ZERO SPEED ( SHEET 1& 2) .
• Unit parameters before & after overhaul 71-79
• Turbovisory parameters Before & after OH . 81-82
• Boiler Safety valve Floating all parameters hourly basis 83-87
• CW Pump BFV Opening / Closing Timings 88
• Gen air leak test Parameters 89
Compiled By Recommissioning Group Page 3

INTRODUCTION

INTRODUCTION
The 1st major annual subsequent to the short shut down for exciter replacement during overhaul
of Unit # 6 was commenced on 23/05/2008 after the Unit was desynchronized at 14:00 Hrs after emptying 9
bunkers except H .Prior to stopping the unit the ATT for safety devices were carried out . Oil injection test was
carried out at 150 MW from Local . The unit was re-synchronized on 18-06-08 at 23:39 hrs (27 days) after
completing all electrical testing & one RHS MS safety valve (SV-8) actual floating . Major activities carried out
during the overhauling are as follows
Area Boiler & ash handling

Coal bunkers inspection and joints strengthening done as per requirement.
One pair coils each from extreme left & right sides of LTSH, Economiser upper, middle and lower banks
lifted for through inspection and tube thickness survey. Repairing of eroded tube, shields and clamps
done. Dislodged coils in RH front panel put back to its place.
Welding of 829 joints (WW-58%, LTSH – 18% , Eco – 12 %, others – 12 % ) done with radiography of
95% joints.
RH tubes internal oxide layer thickness measurement done, no abnormality found.
Additional thermocouples installed in RH outlet tubes inside pent house as per list provided by COS.
Substitution of angles done at coal burner tips for deflector plates removed earlier
Servicing of 6 drum safety valves, 2 MS safety valves and 1 MS ERV done.
APH baskets cleaned with HP water jet and damaged seals replaced
Damaged NMEJ s in PAPH A&B replaced, eroded duct portions repaired
Inspection of Fan blades and servicing of servomotors done
ESP internals cleaning and repairing done
Complete replacement of coal & oil burners

Removal of deflector plate from the coal nozzles
HP water Jet cleaning for APH Baskets
Furnace cleaning
FA system modifications

Area TG & auxiliaries

TG bearings DPT & UT done , no abnormality found
LPBP SV, HP and IP SV & CV servicing done. HPCV-2 was not opening beyond 88%. Pilot valve
cleaning and valves characteristic checking done
Control fluid replaced
Servicing of Governing system components
Catenary correction done and reference point generated in TG spring deck for monitoring of any
expansion.
No rotor lifting observed at bearings 1,2 & 5. Corrected by cleaning JOP packet holes
Pocket cutting done in TG front bearings pedestal as suggested by BHEL in order to prevent oil
accumulation.
Parting plane leakage in HPH-6A rectified.
Condenser flood test done and identified air ingress points attended.
Passing High energy drain serviced / replaced.
Condenser HP Bullet Cleaning

TD BFP cartridge work .
AREA : Generator and auxiliaries
Generator Rotor Threaded out .
Generator terminal bushing inspection done
CC bolt leakages checking – Generator rotor found OK , exciter rotor leakage attended
Generator wedge deflection, ELCID test, DP/UT of retaining ring done.
One locking shoe of turbine end overhang of generator had come off-repaired.
Air gap seal ring clamp welding failure detected –re-welding done.
Dents found in 1st stage fixed blades of compressor of Generator. Damaged blades replaced/
AREA : Electrical / C&I Area
XFMR OH checks
GT OH works /inspections
Switchgear, HT/LT Motors and Motorized Actuators servicing done.
Battery capacity done
Testing & Calibration of field instruments carried out.
DCDB overhaul one section

AREA :OFFSITE
Cold basin cleaning
CW duct draining & inspection of CW valves
AREA : ESP & Ash Handling
Bottom Ash & Fly handling systems inspected a& repaired.
Still air charging of ESP Fields
Being the 1st annual overhauling of the Unit, many deficiencies in the system were identified & they were
attended. Some modifications were carried out for improving the reliability & safety of the unit as described in the
following sections. Some modifications are still required for better operation & maintenance aspects which are
recorded. Most important among them is the Comprehensive checking of protections, inter locks & alarms of the
equipment's were carried out . Testing for Actual Over speed Test of TDBFP A/B ( 24 th May 08) , ATT for safety
devices & Valves after synchronization carried out . All the electrical SWGR remote operation check was carried
out successfully . Recommissioning activities were carried out under the supervision of Shri R.N.Das Sr. Supdt
(Oprn) & under the guidance of Shri S. Bandhyppadhya DGM (O) and Shri D Sarkar AGM (O ) .
( R.N.Das )
Sr Supdt(O)
Recom Team Leader

OVERHAULING TEAM

UNIT # 6
OVERHAULING TEAM
Sl. No. Name Group Designation

1. Sh. R. N. Das Gen Sr. Supdt. ( Team leader )
2. Sh V.Mohan C Sr. Supdt. ( Dy Leader )
3. Sh K.Ch Satyanarayana B Supdt (O)
4. Sh.SS Mahallick B Sr. Engr.,
5. Sh.Abdus Salam C Sr. Engr.
6. Sh P.K Chourasia A Sr Engr
7. Sh P.Naga Suresh C Sr .Engr.
8. Sh P. Ramesh D Engr .
9. Sh KSR Krishna Kumar B Engr.
10. Sh N C Murmu Gen Sr Asst Controller (O)
11. Sh G pradhan A Operator,(Elect)
12. Sh A. Prusty C Operator,(Elect)
13. Sh NK.Sahoo D Operator,(Elect)
14. Sh P.C Pani B Operator, (Elect)
15. Sh A.K Sahoo A Operator,( TG)
16. Sh Nekuri Pradhan B Operator, (TG)
17. Sh Golekh Sahoo C Operator, (TG)
18. Sh D. Roul D Operator,(Blr)
19. Sh S.K Pani B Operator,(Blr)

HISTORY OF THE UNIT

TALCHER SUPER THERMAL POWER STATION

STAGE II (4 x 500 MW)
HISTORY OF STAGE- II UNITS
Description. Unit # 3 Unit # 4 Unit # 5 Unit # 6

MNW Jul’02 May’03 Nov’03 May’04
BLU ACTUAL 11.09.02 05.07.03 18.01.04 27.09.04
Delay(approx) 2 Months 2 Months 2 months 4 months
MNW 3rd Nov ‘02 Sept’03 Mar’04 Sept’04
With oil 04.01.03 25.10.03 13.05.04 06.02.05
47 months 23 54 months 10 63 months 3
Synch with Coal
No of months from “0” date 38 months 1 day

days days days
With coal 20.02.03 19.11.03 14.06.04 30.03.05
39 months 17 48 months 55 months 64 months
No of months from “0” date
days 16 days 11 days 27 days
3 months 2 months 3 months 11 6 months 27
Delay w.r.t MNW
17 days 16 days days days
BLU to synchronization in oil ( in no of
115 112 115 132
days )
Synch to coal firing( in no of days ) 45 25 32 52
Full load achieved 26.03.03 14.01.04 21.08.04 08.07.05
BLU to full load

196 193 215 284
( in no of days )
Synch to full load 81 81 100 152
17-05-06 to-
Last short Overhauls 30-05-06
12 days
TRIAL OPEARTION OF THE UNITS
Description Unit # 3 Unit # 4 Unit # 5 Unit # 6

As per MNW FEB’03 DEC’03 JUN’04 DEC’04
Start 02. 07. 03 29. 01. 04 14.08.04 08.07.05
Trial
Complete 16. 07. 03 19. 02 .04 28.08.04 30.07.05
operation
Duration 14 days 21 days 15 days 22 days
Delay w.r.t MNW 5 months 2 months 2months 7 months
BLU to T O Completion .
306 229 222 306
( in no of days )

Various Protocols &

Recommissioning Check
Lists Used

VARIOUS PROTOCOLS USED

Sl no DESCRIPTION STATUS Sl no DESCRIPTION STATUS
• BOILER SIDE PROTOCOLS 29. PRIMARY AIR DUCT TO MILLS LHS
BURNER VALVES PASSING CHECK 30. PRIMARY AIR DUCT TO MILLS RHS
1.
PROTOCOL ( CHECKED EARLIER ) 31. ACTUAL SAFETY VALVE FLOATING
BOILER EXPANSION INDICATOR STILL AIR CHARGING OF ESP PASS
2. 32.
FIXING A/B/C/D PROTOCOL
BOILER EXPANSIONS READINGS AT
3.
VARIOUS LOADS • TG SIDE PROTOCOLS
BOILER DRUM INTERNAL INSPECTION MAIN TURBINE ACTUAL OVER SPEED
4. 33.
PROTOCOL TEST PROTOCOL
IGNITOR/SCANNER/OIL GUN CHECKS TDBFP – ‘A’ ACTUAL OVER SPEED
5. 34.
FROM INSIDE . TEST PROTOCOL
BURNER TILT REMOTE CHECK TDBFP – ‘B’ ACTUAL OVER SPEED
6. 35.
PROTOCOL TEST PROTOCOL
BURNER TILT INSIDE CHECK 36. GENERATOR H2 PURGEOUT
7.
PROTOCOL HOTWELL INTERNAL INSPECTION
37.
SADC CHECKS LOCAL /REMOTE PROTOCOL
8.
PROTOCOL FST & D/A INTERNAL INSPECTION
38.
9. APH WATER WASHING PROTOCOL PROTOCOL
10. APH WATER WASH NOZZLE CHECK SDFT/UFT/LPFT/HPFT INTERNAL
39.
INSPECTION PROTOCOL
APH OIL CARRYOVER PROBE
11. CONDNSER WATER BOX INSPECTION
AVAILABILITY 40.
WITH OLTC SCREEN
APH AUXILIARIES AVAILABILITY
12. ATT F FOR SAFETY DEVICES
CHECK 41.
CHECKING PROTOCOL
13. AIR MOTOR AUTO START CHECK ATT FOR VALVES CHECKING
14. APH CLEANILINESS CHECK 42.
PROTOCOL
15. APH SOOT BLOWER CHECK 43. TG GOV CHARECTERISTICS
16. APH FIRE ALARM CHECK 44. LPBP EHC CHARECTERISTIC
17. FURNACE WALL CLEANLINESS 45. TDBFP A/B EHC CHARECTERISTIC
18. FURNACE AIR TIGHTNESS TEST 46. MOT INSPECTION
19. OIL GUN / IGNITER READINESS CHECK 47. TDBFP EXHAUST VALVES CHECKS
WALL BLOWER NOZZLE CHECK 48. GENERATOR AIR TIGHTNESS TEST
20.
FROM INSIDE 49. PRIMARY WATER FLOW ADJUSTMENT
21. WINDBOX AIR TIGHTNESS TEST
SECONDARY AIR DUCT FROM FD FAN • ELECTRICAL SIDE PROTOCOLS
22. 50. GENERATOR REALY TESTING
DISCAHRGE TO APH INLET
SECONDARY AIR DUCT FROM APH 51. GT/UT PROTECTIONS & INTERLOCKS
23.
OUTLET TO WINDBOX 52. DG SET & SWGR BREAKERS
PRIMARY AIR DUCT FROM PA FAN
24. 53. PROTOCOLS FOR TRANSFORMERS
DISCAHRGE TO APH INLET
PRIMARY AIR DUCT FROM APH PROTOCOLS FOR GENERAL
25. 54.
OUTLET TO MILL INLET CHECKINGS OF MCC / SWGRS
FG DUCT FROM ECONOMISER OULET PROTOCOLS FOR MOTOR TB
26. 55.
TO APH INLET INSPECTION
FG DUCT FROM APH OUTLET TO ESP 56. MULSIFIERS CHECKINGS
27.
INLET
FG DUCT ESP OUTLET TO CHIMNEY
28.
INLET

Details of Recommissioning check Lists Followed

During Annual Overhaul
Sl Sl
Check list details Status Check list details Status
no no
AA 13. TDBFP A/B isolation /normalization
GENERAL 14. TDBFP centrifuges.
Unit Integrated Startup check list after Annual 15. Deaerator
1. Overhaul ( Separate Book) 16. LP/HP Feed Water Heaters
(Blr/TG/Elect/Off/ESP/Ash/ESP/OFF Site etc ) 17. TG Lub /Jacking oil system shutdown checks
BB BOILER system. 18. MOT filling
1. Boiler Force Cooling check list 19. Main oil Centrifuge .
2. APH water washing check list Main TG Lub oil system line up checks including
20.
3. Boiler 1st pass internal water washing check auxiliaries
4. Boiler 2nd pass internal water washing check 21. Check List for TG Lub Oil system Flushing
5. Furnace pressurization test . 22. Putting TG set on barring gear
6. FG duct inspection details 23. Condenser vacuum pulling.
7. Boiler Hyd Test Valves readiness check list 24. Stator water system
8. Boiler Hydraulic Test check list 25. Gen air tightness test .
9. ID Fan A/B H2 Gas system filling (Air purge out with CO2 &
26.
CO2 Purge out with H2 & H2 pressurization .)
10. FD fan A/B
27. Seal oil system
11. PA Fan A/B
28. HP BP System
12. SAPH A/B
29. TG set Rolling Preparation
13. PAPH A/B
30. TG set Rolling
14. BCW pumps A/B/C system
15. SA Duct checking details EE OFFSITE SYSTEM
16. PA Duct checking details 1. CST line up checks NA
17. FG Duct checking details 2. CW Pump isolation & normalization
18. Hopper Inspection details 3. CW duct draining & charging
19. Mill isolation details 4. CT Isolation & normalization
20. Mills A-K recommissioning status / readiness.
21. Feeders A-K recommissioning status / readiness.
FF • Electrical system
22. HFO/LDO oil system at 17 Mtr. • HT SWGRS (11 KV/3.3 kv)
23. Burner front checks 1. UA SWGR Unit - 3
24. SH/RH Spray system 2. UB SWGR Unit - 3
25. Mill seal air system 3. UAA SWGR Unit - 3
26. AC/DC Scanner air fans
27. LDO/HFO Nozzle valve passing test. • LT SWGRS TG SIDE
C 1. USS SEC A/B
ESP & ASH Handling system 2. SSS SEC A/B
1. BA system check list 3. TMCC SEC A/B
2. FA system check list 4. TACDB SEC A/B
3. ESP pass A / B / C /D Check List 5. UES
6. TVDC
DD TG system
1. TG actual Over speed test • LT SWGRS SG SIDE
2. TDBFP A/B Actual Over Speed Test 7. BLR MCC SEC A/B
3. ATT for safety Devices 8. COAL MILL MCC SEC A/B
4. ATT for Valves 9. BACDB SEC A/B
5. Condenser Vacuum Killing
6. Turbine Force Cooling
7. Condenser Flood Test
SG/TG ECW System with Chemical Dosing
8.
System
9. DM Makeup /Emergency Make up water system
10. CEP A/B/C isolation / Normalization
11. Condensate System
12. MDBFP – C isolation /Normalization

RECOMMISSIONING
HIGHLIGHTS

UNIT- 6 RECOMMISSIONING HIGHLIGHTS

1st Annual Overhaul.
(23 -05 - 08 to 18 – 06 - 08) 27 days
Sl Description of the No of days

Actual date Remarks
no milestone activity aft S/D
1. Unit Stopped 0 23-05-2008 At 14:00 Hrs
Barring Gear Stopping & Lub
2. 6 29-05-2008 At 11:20 hrs
Oil system
3. Internal Hydro test 19 11-06-08 At 15:30 Hrs , 220 ksc
4. External Hydro 20 12-06-08 At 1
5. Condenser Flood test 15 08/06/08 At 20:00hrs
TG lub Oil Flushing
6. 26 17/06/08 At 11:00hrs
completion
7. TG put on barring gear 26 17/06/08 At 11:40hrs
1& 23/06/08& At 16:52hrs
8. Furnace air tightness test
26 17/06/08 At 01:30hrs
9. Boiler Light Up 26 17/06/08 At 14:47hrs
At 03:38hrs, MS SV-8 actual floating
10. Safety Valve Floating 27 18/06/08
was done at 186.26ksc.
TG set 1st Rolling to 360 RPM After Steam Purity < 20 ppb
11. 27 18-06-2008
for soaking At 11:30hrs
TG set 1st Rolling to 3000
12. 27 18-06-2008 At 16:02hrs
RPM for Electrical testing
13. Electrical testing 27 18-06-2008 At 20 :30 Hrs
14. ATT testing 27 18-06-2008 At 20 :40 hrs -20 :55 Hrs
At 21:15 Hrs ( OS trip test device
15. Local Oil Injection Test 27 18-06-2008
MCC problem)
At 21 : 41 Hrs To observe the
16. Turbine Hand Trip 27 18-06-2008 coasting Down Vibration & Brng
pedestal Vibration
Speed raised after 254 RPM , kept
Final TG set Rolling for
17. 27 18-06-2008 at 360 for some time & then raised
synchronization
to 3000 RPM reached 23:05
18. Unit Synchronization 27 18-06-2008 23:39 hrs after Excitation Testing
Could not be achieved as per
19. Full Load Operation normal ramp up of the Unit due to
coal feeding problem.
Because of coal feeding problem the Unit full load operation could not be
achieved as per normal ramp up of the Unit .

UNIT- 6 RECOMMISSIONING ACTIVITIES.
Start Complete
Sl Duration Cumulative
Description of the activities Date Time in Time in
no in Hrs Time in Hrs
Hrs Hrs
1. BLU ( Boiler Light Up) 17/06/08 14:47
2. 100 Ksc Pressure reached 17/06/08 23:45
3. Pressure rising to 160 18/06/08 1:00
Treavy test Completed for all 8
4. valves at 150 ksc + Popping of 18/06/08 3: 20
MS & / HRH ERVs
Pressure raised to 186 ksc for
5. actual Safety valve floating one 18/06/08 03:38
number
6. Parameter reduction 18/06/08 03:38
Achieving Rolling parameters
7. 18/06/08 6:05 Hrs
including steam Purity
TG speed raised to 360 rpm &
8. soaking at 360 RPM for achieving 18/06/08 11:20hrs 11:30hrs
X6 Criteria
9. Raising TG speed to 3000 rpm 18/06/08 15:55hrs 16:02hrs 6 min
10. Elect. Testing 18/06/08 16:20 20:20 4 Hrs
ATT for Safety Devices at 3000
11. 18/06/08 20:40 20:55 15 Min
RPM
12. Turbine Hand Trip 18/06/08 21:42
TG set rolling to 360 rpm &
Raising to 3000 RPM & Voltage
13. 18/06/08 23:39
Checking in Ch 1 & 2 & Unit
synchronization
Last overhauls total time from BLU to Synchronization
• U-5 Overhaul (June ’06) = 28:34 Hrs

• U-4 Overhaul (Dec ’06) = 32: 24 Hrs
• U-3 overhaul ( August’07) = 27:24 Hrs
• U-6 Overhaul ( June ’08 ) = 32:52 Hrs , Only MS safety valves actually floated

MODIFICATIONS /
IMPROVEMENTS CARRIED OUT

MODIFICATIONS /IMPROVEMENTS CARRIED OUT

DURING ANNUAL OVERHAULING
Area : Boiler & Auxiliaries

1. PA.header pr. Low to mill tripping 2/3 modification (instead of 1/2)
2. P-13 24v supply fault alarm provided in LVS
3. Mill SA/bowl DP low alarm provided in facia
4. Top mill trip runback 1st mill instantaneous , followed by next mill after2 sec till 5 mill operation
5. Introducing SBC temp permissive at 270 dec with 20m time delay
6. DC scanner fan running alarm provided in LVS
7. MFT discrepancy alarm provided in LVS
8. Any BIG not open to mill tripping time delay (15 m ) introduced
9. Top mill trip from any PA fan tripping runback modification
10. All id fan to MFT tripping 2 sec time delay introduced
11. Mill protections bypassing for trial run from HMI introduced
12. Mills LOP changeover logic modification
13. Feeder control supply provided from UPS .
14. Mills first out logic provided .
15. All coal burners shield plate were cut as per recommendation of OS .
16. PA/FD fan suction Hood were extended & approach platforms are provided for cleaning .
17. Additional thermocouples are installed in RH Coil – 70 in addition to the existing ones . Points are
available at local .
18. The following steps were taken for early silica stabilization in the Unit .
Complete cleaning & flushing of hot well.
CEP suction header draining & flushing keeping the suction strainer open
Deaerator hot draining after Hyd Test , cleaning , flushing
Complete Draining of boiler after hydro test .
Hot blow off from Bottom Ring header carried out at 10 ksc pressure
19. Complete Operation checking carried out for all 4 FG inlet dampers to APH & LS adjustment done
at full open/close position . Afterwards they are selected in Maint Mode to avoid inadvertent
operation .
20. All ESP Inlet /Outlet & other gates LS adjustment were carried out in Open & close position
21. All 4 eco bypass gates remote operation were checked & finally at full close position their power
supply is kept off .
22. Additional pockets ( 4 nos on each side LHS/RHS) for thermocouples mounting are provided in
the common FG duct to ESP inlet on LHS/RHS on the duct top portion .
23. Ladders are provided in wind box for inspection of SADC from inside .
24. Bunker level indication were provided in “Fuel Overview Page” for operational flexibility
25. All bracings in FG duct are provided with sacrificing angles to reduce erosion on main bracing
members .
26. All 10 bunkers external welding inspection through DP test & repair carried out .

Area : Turbine & Auxiliaries

1.
RADAR type level transmitter installed for MOT level measurement.
2.
One second delay introduced in Fire protection push button 1 &2
3.
LPBP sliding set point characteristic changed as per the new curve. 45.85 KSC ( AS PER OS )
4.
Gen Aux. logics modification done
5.
Power supply scheme of CJJ-05/06 modified for redundancy
6.
Trip related switches in CEP,TDBFP & Main TG replaced with reliable imported switches.
7.
DC SOP logic modification for "Genrerator on purge" condition.(VPC implemented)
8.
Remote indication of TDBFP lub oil tank level provided
9.
Remote indication of vacuum pump suction & ejector valve limit switch.
10.
HPT evacuation line MTM thermocouple fixed & measurement provided in UCB
11.
LPBP trip to manual LVS alarm provided.
12. Pocket cutting done in TG front bearing pedestal as suggested by BHEL in order to prevent oil
accumulation
13. CFP 1 & 2 Fault indication on Module isolation was not appearing , attended by EMD / C&I .
14. Actual Over speed test of TDBFP- A was carried out on 24/05/08 , the acting speed was 5986
RPM . Oil injection test was carried out at 5000 RPM .
15. Actual Over speed test of TDBFP- B was carried out on 24/05/08 , the acting speed was 5876 RPM
. Oil injection test was carried out at 5000 RPM .
16. ATT for safety devices carried out successfully on load before Unit shutdown at 150 MW load
.However while carrying out after rolling to 3000 RPM problem experienced with OS Motor Module
. To be checked .
17. HPBP OSU modification was carried out by TMD for easy of maintenance .
18. During boiler hydro-test the temp. of MDBFP Main Pump Thrust Bearing was maintained low by
maintaining FST temp < 85 0 C . This was possible by taking fresh makeup to D/A on continues
basis
19. TG “ – ve Mtr “ below flash box area was cleaned thoroughly .
20. Approaches in various areas of TG side were provided like near Gov Rack , etc
21. Oil Canal permanent lighting provided .
22. APRDS graphic page is modified as per the existing scheme .
Area : Electrical
23. All description corrections were made in 11 kv UA/UB swgr .
24. Staggering of power supply to coal feeders in alternate way i.e. coal feeders ACEGJ from Section-A and
BDFHK from Section-B of Boiler ACDB done

25. All SWGRs incoming breaker remote operation were made through , Changeover through TSS
was checked & made available for all SWGRs .
26. Equipment Power supplies are changed to different feeders for improving reliability
3 phase supply
Equipment From To Equipment
rearranged as follows
Primary water 11.18F/TMCC
2.18R/TMCC Sec-A Feeder-A BACDB Sec-A 1R-B
pump-A Sec-B
TDBFP-A
2.18R/TMCC 2.8R/USS Sec-A Feeder-C BACDB Sec-A 1F-C
Centrifuge
10.18F/TMCC
TDBFP-B AOP-1 3.18R/USS Sec-A Feeder-E BACDB Sec-A 1F-D
Sec-B
3.18R USS
CST pump 10.18F/TMCC Sec-B Feeder-G BACDB Sec-A 1F-B
Sec-A
BACDB Sec-A
Feeder-B BACDB Sec-B 8F-H Feeder-J BACDB Sec-A 1R-C
1F-B
BACDB Sec-B
Feeder-G BACDB Sec-A 1F-B Feeder-B BACDB Sec-B 8F-H
8F-H
BACDB Sec-A
Feeder-D BACDB Sec-B 9R-C Feeder-D BACDB Sec-B 9R-C
1R-C
BACDB Sec-B
Feeder-J BACDB Sec-A 1R-C Feeder-F BACDB Sec-B 8R-C
9R-C
Battery charger-1 USS Sec-B USS Sec-A Feeder-H BACDB Sec-B 9R-B
Alternate
supply from
24V DC to ESP
24V C&I Feeder-K BACDB Sec-B 9R-D
A/C PLC
charger DCDB
1&3
Area : ESP & Ash handling
27. FA system Vacuum Line Modification carried out to make independent VP & CT . In this process the
VP suction valve & AW IV were removed from the system . Double VT provided for each pass .
28. Eco Bypass duct total ash was evacuated through the system , thus avoiding ash dumping outside .

MAJOR PROBLEMS DURING

RECOMMISSIONING

MAJOR PROBLEMS EXPERIENCED

DURING RECOMMISSIONING.
AREA : BOILER & AUXILIARIES

SAF –A actuator was placed in reverse manner so that with fan starting it was closing & with fan
1.
running this was closing , rectified .
Inadequacy of Fire water was experienced during simultaneous boiler washing & APH water
2.
washing causing delay in the system .
Simultaneous work in Eco bypass duct cleaning & LTSH Zone of 2nd pass pressure parts have been
3.
affected with dust
During APH water washing the Zero meter area got flooded as the Hopper Drains are not provided
4.
for the above purpose .
5. Also the duct & other equipment are getting damaged due to falling of acidic water from the APH .
The Drain Back side of PA/FD fan is getting clogged with CHP coal as the reject chute of CHP is
6.
just above the drain .
Hot air Common duct Ash removal was having problem as no separate system made available like
7.
that of Eco Bypass System .
Operation of dampers at ESP inlet & outlet, ID fan inlet are unsafe as vertical ladders are not provided
8.
with cage.
ESP field earth keys were found not available for Pass-A (E1) 2,16,17, Pass-B (E2) 7,Pass-C (E3)
9.
1,5,6,7,9,11,12 and Pass-D (E4) 1,5,15,17
AREA : TG & AUXILIARIES
10. Generator Exciter Coolers are not having drains . TMD informed
Duct draining inlet side was not possible as ICV ‘s were passing . Even after 4 days of draining it
11.
was not possible .
CW outlet duct needs to be drained by loosening the dummy flanges as there is no provision of
12.
permanent drains outlet
OTHERS
13. Approach to certain valves , dampers area are still to be provided . The list is enclosed .
14. Condenser - ve mtr final finishing is not done causing water & sludge accumulation .

Surprises & Learning’s on

Boiler & TG systems

Surprises & Learning’s on

Boiler & TG systems
SL.NO. AREA OBSERVATION

Not rotor lifting observed at bearings 1,2 & 5. Blockage in JOP
01 Turbine
packet holes cleared and the lift made OK.
Exciter rotor balancing weights suspected to be missing their slot.
02 Generator
Matched with balancing weight of the machine, found OK.
One locking shoe of turbine end overhang of generator had come
03 Generator
off-repaired.
Rotor 1st stage fixed blades of compressor have dents, damaged
04 Generator
blades replaced.
05 Generator Air gap seal ring clamp welding failure detected-re welding done.
Suspected escaping of exciter rotor balancing weight – after
06 Generator investigation it was construed that the balancing weight was not
placed at the place without paint, creating false impression.

NEW METHODS / PROCEDURES

ADOPTED DURING THIS
OVERHAUL.

NEW METHODS / PROCEDURES ADOPTED

DURING THIS OVERHAUL.
BOILER & AUXILIARIES

• Trial run of ID/FD/PA fans by opening manholes , closing APH Inlet gates /dampers , ESP Outlet gates
for ID fan .
• Furnace pressurization test after 2 hrs of Boiler shutdown to identify the leakages before overhaul .
Again it was carried out after all overhaul activities were completed .
• Running of one ID fan after APH water washing to facilitate smooth boiler internal water washing .
• Mill clean air flow tests were carried out subsequent to Furnace pressurization test before BLU
• Furnace pressurization test was carried out by running only FD fan & ESP inlet gate passing checks
were carried out by opening the manholes down stream .
TG & AUXILIARIES
• During Flood test Water Filled simultaneously through all possible sources which has reduced time .

Suggestions For Further

Improvement

SUGGESTION FOR IMPROVEMENT.
• Boiler inside lighting AC/DC to be taken from the source provided by EMD . Preferably
the source can be from the other running Unit like AESWGR where the direct impact
will not be there on main plant equipments . .
• Proper Approach to CT area main isolating valve & lighting to be provided to do the
necessary isolation & normalization in the Night
• Proper Approach / illumination for SW Blow-down / Chlorination Plant water line valves
near CW ICV are to be provided to carry out the operation in the Night .
• Gravity draining facility for CW duct ( ref the sketch). This will reduce the drain timings of
duct to a larger extent .
• Permanent power supply source for temporary dewatering pump in the Condenser pit area .
• Separate Drain system for APH hopper during water washing & Eco Ash Hopper during
2nd pass water washing .
• Permanent Dewatering Pump power supply source for the CT Basins from the Adjacent
Units so that Cold Basin dewatering & subsequent cleaning will not be affected when
CTMCC goes under PTW.

IMPORTANT EVENTS

IMPORTANT EVENTS
During Unit Annual Overhaul
AREA : BOILER
Day Completion Of
Sl. Start Of Activity Duration in
Description aft Activity
No Hrs
S/D Date Time DATE TIME
1. Unit Shut Down for OH 1 23/5/08 14:00 23/5/08 19:38 05:40
Pent House Pressurize fan kept in
2. 1 23/5/08 20:00
service
3. APH Water Washing all - 4 1 23/5/08 20:00 24/5/08 03:30 7:30
4. APH Drying 2 24/5/08 04:00 24/5/08 10:00 06:00
5. All BCW Pumps Stopped 2 24/5/08 05:44 15:44
6. Boiler Draining 2 24/5/08 11:30
7. Boiler Water washing 1st pass 2 24/5/08 25/06/08
8. Goose Neck area cleaning 2 24/5/08 24/5/08
9. Boiler Water washing 2nd pass 3 25/06/08 20:00 26/5/08 02:00
10. All APH stopped after drying 2 24/5/08 10:00
Eco Bypass Duct Hopper Ash
11. 3 25/5/08 10:00 10/6/08 17:00 16 days
Removal
12. Final Boiler Filling after flushing 26 17/06/08
23/06/08
1& 16:52&
13. Fur Pr test By Running FD fan &
26 01:30
17/06/08
14. ID fan started 26 17/06/08 09:30
15. PA fan started 27 18/06/08 01:08
16. FA system started
17. BLU 26 17/06/08 14:47
Boiler Pressure raising start to
18. 26 17/06/08 21:42
reach 150 ksc ( 40 ksc/Hr )
Treavy test for 8 valves
19. 26 17/06/08
( 6 drum + 2 MS Line)
MS safety valve actual floating (
20. 26 17/06/08 03:38
SV - 8)
21. Pressure Reduction

IMPORTANT EVENTS
During Unit Annual Overhaul
AREA : Turbine & auxiliaries
Completion Of
Sl. Day aft Start Of Activity Duratio
Description Activity
No S/D n in Hrs
Date Time DATE TIME
1. Unit Shut Down for OH 1 23/5/08 14:00
2. CT FAN STOPPING ALL 1 23/5/08 18:00
3. Natural Cooling Of TG SET 1 23/05/08 14:45
4. MDBFP - C Stopped 2 24/05/08 07:00
5. GT Taken out of service 2 24/05/08 12:00
6. 1st CW pump stopping 2 24/05/08 13:15
7. CT 6A isolation (water side ) 2 24/05/08 13:30
H2 depressurization & H2 purge out
8. with CO2 2 24/05/08 05:30 25/05/08 08:15 15hrs
CO2 purge out with Air & maintain

9. 0.5 ksc pressure air pressure , 24 3 25/05/08 08:45 26/05/08 06:00 22hrs
hrs venting
10. Vacuum Killing . 3 25/05/08 18:45 25/05/08 19:15 00:30
11. Force Cooling of TG set 4 26/05/08 01:10 28/05/08 11:20 34
12. APRDS isolation 4 26/05/08 26/05/08 10:00
13. All CEP stopping 4 26/05/08 26/05/08 11:00
14. D/A draining 4 26/05/08 10:51 26/05/08 12:31 01:40
15. SG ECW system stopping 4 26/05/08 26/05/08 11:30
16. Water Box Cleaning # 5 side 4 26/05/08 20:40 27/05/08 10:00
17. Vacuum Pump Stopping 6 28/05/08 10:45
18. CF system stopping 6 28/05/08 10:45
Barring Gear Stopping After HPS
19. 6 28/05/08 11:20
/HPC temp 115 0 C
20. TG ECW system isolation 6 28/05/08 20:00 29/05/08 10:24
21. ACW System Stopping 6 28/05/08 11:35 28/05/08 17:18

Completion Of
No S/D n in Hrs
Date Time DATE TIME
Jop kept in service as per
22. TG Lub Oil system stopping 6 28/05/08 12:10
TMD requirement
2nd CW pump stopping ( after
23. 8 30/05/08 12:18
alignment job was completed)
Gen conical Filter cleaning after
24. 9 31/05/08 09:30
draining the system up to the level
25. Water Box Cleaning # 7 side 9 31/05/08 13:30
26. TG ECW system starting 12 03/06/08 19:25 For CF Flushing
27. SG ECW system starting 13 04/06/08 20:00 P&I Check
Final Hotwell draining after Flood
28. 16 08/06/08 20:30
test
29. SW Unit Resin Replacement 16 07/06/08 11:00 07/06/08
30. Condenser flood test 17 08/06/08 16:30 08/06/08 20:30 4:00
31. Final Hotwell filling after flushing 17 09/06/08
32. Final D/A Filling after flushing 17 09/06/08 12:00
33. 1st CW Pump started 18 10/06/08 10:30
34. MDBFP starting for Hyd test 19 11/06/08 13:45
35. ACW System Starting 19 11/06/08 10:00
36. CF system starting 20 12/06/08 10:00
37. TG Lub Oil flushing 25 16/06/08 23:50 17/06/08 10:50 11:00
38. Condensate system charging 26 17/06/08 11:25 After Hotwell Flushing
After TMD clearance for APH
39. APRDS Charging 26 17/06/08
SB testing with steam
40. Machine put On Barring Gear 26 17/06/08 11:40 17/06/08 12:20 00:30
Air purging with Co2 filling till CO2
41. 26 17/06/08 03:00 17/06/08 15:30 12:30
purity 98%
Co2 Purging with H2 filling till H2
42. 26 17/06/08 16:00 18/06/08 02:00 10:00
purity 97-98%
H2 pressurizations after achieving
43. 27 18/06/08 02:00 18/06/08 05:00 03:00
purity to 3.3 ksc
6:00 H2 pressure drop testing was
44. Ready For Rolling 27 18/06/08
hrs carried out
Turbine Roll To 360 Rpm & soaking
45. 27 18/06/08 11:30 18/06/08 15:55 4:25
at 360 RPM

Completion Of
No S/D n in Hrs
Date Time DATE TIME
46. Speed raising to 3000 RPM 27 18/06/08 15:55 18/06/08 16:02 00:07
47. Electrical testing 27 18/06/08 16:15 18/06/08 20:30 04:15
ATT for safety device after
48. 27 18/06/08 20:40 18/06/08 20:55 00:15
Electrical Test
Turbine Trip after electrical testing (Through actuation of
49. 27 18/06/08 20:41
& ATT electrical trip)
50. GT Back Charge 27 18/06/08 21:00
51. UT A/B Charged 27 18/06/08 23:30 Breaker problem attended
Turbine Rolling after parameter
52. 27 18/06/08 22:55 18/06/08 23:02 00:07
attained to 3000 RPM
53. Unit Synchronisation 27 18/06/08 23:39 After excitation system check.
54. Load 500 MW 32 23/06/08 17:00 After Coal position improved

CW & COOLING TOWER OVERHAULING ACTIVITIES
JOB No of day after DURATION

Sl NO. EQUIPMENT
DESCRIPTION Shutdown
FROM TO
1. CT- A Fans stopped 1 23/5/08
2. CT- B Fans stopped 1 23/05/08
3. CT- A Water Isolation 2 24/05/08
4. CT- B Water Isolation 9 31/05/08
5. CW pump -A Stopping 1 23/05/08
6. CW pump -B Stopping 9 31/05/08
7. CW pump -A Starting 19 10/06/08
8. CW pump -B Starting 26 17/06/08
Water side
9. CT- A 9 31/05/08
charging
Water side
10. CT- B 15 06/06/08
charging
11. CT- A Fans starting 26 17/06/08
12. CT- B Fans starting 26 17/06/08
13. ICV 1 / 2 Closing 2 24/05/08
14. ICV 1 / 2 Opening 27 19/06/08

DETAILS OF JOINT INSPECTIONS

CARRIED OUT

LIST OF INSPECTIONS IN BOILER SIDE

Sl no Details of Check /Inspection Final Date Remarks
1. Drum Internal Inspection 05/06/08
2. Bottom Ring Hdr Inspection 10/06/08
3. Wall blower check from inside 09/06/08 All are kept at 38mm
4. Oil Nozzle v/v passing Check N/A
FG Ducts
Flue gas duct inspection from Economiser
5. 14/06/08 Cleaning was done
outlet to APH inlet. LHS
Flue gas duct inspection from Economiser
6. 14/06/08 Cleaning was done
outlet to APH inlet. RHS
Gate protection plates / expansion
7. APH outlet to ESP inlet LHS 14/06/08 joints were repaired and duct
cleaning done.
Gate protection plates / expansion
8. APH outlet to ESP inlet RHS 14/06/08 joints were repaired and duct
cleaning done.
9. Eco bypass duct inspection LHS/RHS Done
10. FG duct ESP outlet to ID fan inlet LHS 14/06/08
11. FG duct ESP outlet to ID fan inlet RHS 14/06/08
12. FG duct ID fan outlet to chimney 14/06/08
PA Ducts
13. Air duct from PA fan – A to APH inlet . 09/06/08 Duct cleaning done
14. Air duct from PA fan – B to APH inlet . 09/06/08 Duct cleaning done
15. Common Cold Air Duct 09/06/08 Duct cleaning done
LHS/RHS common hot PA duct
16. Common Hot Air Duct 09/06/08 expansion joint replaced and duct
cleaning done
17. PA duct from APH to mills. LHS 14/06/08 Duct cleaning done
18. PA duct from APH to mills. RHS 14/06/08 Duct cleaning done
19. Duct to Mills 13/06/08 Duct cleaning done
SA Ducts
20. Air duct from FD fan – A to SAPH inlet 09/06/08 Duct cleaning done
21. Air duct from FD fan – Bto SAPH inlet 09/06/08 Duct cleaning done
22. Air duct SAPH – A inlet to inlet to wind box. 09/06/08 Duct cleaning done
23. Air duct SAPH – B inlet to inlet to wind box. 09/06/08 Duct cleaning done
24. Cold air interconnection duct 09/06/08
25. Hot air interconnection duct 09/06/08
26. SCAPH inspection PSCAPH - A 25/05/08
27. SCAPH inspection PSCAPH - B 25/05/08
28. SCAPH inspection SCAPH - A 25/05/08
29. SCAPH inspection SCAPH - B 25/05/08
Burner Front Checks
30. Final SADC Checking 0/50/100 % 15/06/08

Sl no Details of Check /Inspection Final Date Remarks

31. Final Burner tilt Checking 0/50/100 % 10/06/08
32. Igniter Position Checking from inside 12/06/08
33. Scanner Position Checking from inside 12/06/08
APH Checks
SAPH- A Fire Fighting system Nozzle
34. 17/06/08
inspection
SAPH- B Fire Fighting system Nozzle
35. 17/06/08
inspection
PAPH- A Fire Fighting system Nozzle
36. 17/06/08
inspection
PAPH- B Fire Fighting system Nozzle
37. 17/06/08
inspection
SAPH- A Soot Blower Operation Check
38. 15/06/08
from inside
SAPH- B Soot Blower Operation Check
39. 15/06/08
from inside
PAPH- A Soot Blower Operation Check
40. 15/06/08
from inside
PAPH- B Soot Blower Operation Check
41. 16/06/08
from inside
SAPH A/B – SB Nozzle checking with steam
42. 15/06/08
change
PAPH A/B – SB Nozzle checking with steam
43. 16/06/08
change
ESP & Ash Handling Checks
44. BA hopper Nozzle checking 14/06/08
45. BA hopper inspection. & box up 16/06/08
46. Setting Bin inspection & box up 14/06/08
47. Eco hopper inspection 15/06/08
48. Eco Bypass hopper inspection 15/06/08
49. APH Hopper inspection ( all 10 nos) 16/06/08
50. ESP hopper inspection Pass - A 10/06/08
51. ESP hopper inspection Pass - B 10/06/08
52. ESP hopper inspection Pass - C 13/06/08
53. ESP hopper inspection Pass - D 13/06/08

LIST OF INSPECTIONS TG SIDE
Sl no Details of Check /Inspection Start date Remarks

1. Deaerator /FST Internal Inspection 03/06/08
2. Hotwell inspection after cleaning 04/06/08
3. TDBFP-A exhaust v/v internal inspection 04/06/08
Rupture diaphragm of TDBFP-
B exhaust was found to be
4. TDBFP-B exhaust v/v internal inspection 04/06/08
damaged and the same was
replaced.
LPT last stage blade & Below inspection inside
5.
steam space
CFT oil drained to empty
6. CFT tank inspection after draining & cleaning 09/06/08 barrels.
After flushing oil was removed.
7. MOT inspection after cleaning 03/06/08
Condenser Water Box Cleaning & Inspections After this flood test inspection
8. 08/06/08
# 7 side Top/Bottom was again carried out.
Condenser Water Box Cleaning & Inspections
9. 08/06/08
# 5 side Top/Bottom
Condenser In let / outlet Valves seal ring After seal ring replacement in
10. 09/06/08
inspection corner 3&4
11. LP Flash tank inspection N/A Not done
12. HP flash tank inspection N/A Not done
13. SDFT flash tank inspection N/A Not done
14. UFT inspection 16/06/08
15. OLTC-A screen inspection & opn check # 7 side 09/06/08
16. OLTC-A screen inspection & opn check# #5 side 09/06/08

DETAILS OF TESTINGS
CARRIED OUT

List Of Testing Carried Out

No of Day Testing
Sl no Details of Equipment Remarks
aft S/D Date
• Boiler & Auxiliaries
13/06/08&
1. ID Fan – A VFD testing 22&23
14/06/08
13/06/08&
2. ID Fan – B VFD testing 22&23
14/06/08
Pressurized up to 221ksc for
3. Boiler Hydro test Internal at 200 ksc 20 11/06/08
10minutes.
4. Boiler Hydro test External at 259ksc 21 12/06/08
23/05/08 & Pressurized up to 124mmwc
5. Furnace pressurization test 1&25
16/06/08 Pressurized up to 70mmwc
2B & 9A DC low voltage problem
6. Still air charging of ESP pass - A 21 12/06/08
attended.
7. Still air charging of ESP pass – B 22 13/06/08 6A DC low problem attended
8. Still air charging of ESP pass – C 24 15/06/08 C-2B tripping on check oil
9. Still air charging of ESP pass - D 24 15/06/08 9A sparking intermittently
Safety valve testing ( only one MS SV 03:38hrs SV-8 MS safety valve actual
10. 26 17/05/08
actual floated ) floating done. Operated at 186.26ksc
• TG & Auxiliaries
Oil injection test carried out and
11. Oil injection test for main Turbine 27 18/06/08 found OK (OIL pr 1.4/2.4ksc
respectively)
12. Main TG actual over speed test
13. Oil injection test for TDBFP- A 1 23/05/08 Test done at 5443 rpm
14. TDBFP – A actual over speed test 1 23/05/08 Turbine tripped at 5982 rpm
Could not be successful (Test oil pr
15. Oil injection test for TDBFP- B 1 23/05/08
is not developing)
16. TDBFP – B actual over speed test. 2 24/05/08 Turbine tripped at 6056 rpm
17. TDBFP – A EHC characteristic check 16/06/08
18. TDBFP – B EHC characteristic check 16/06/08
19. Condenser flood test 17 08/06/08 Filled up to bottom of LP turbine desk
20. Air leak test of Generator 24 15/06/08
Final Main TG EHC characteristic check (
21. 15/06/08
Gov system overhauling was done )
22. Electrical test of Generator 27 18/06/08
Before unit shutdown and before
23/05/08 synchronization ATT for safety valves
23. ATT for safety devices 1&27
18/06/08 carried out at 3000rpm (RTD-1/2,
Low vac device,O/S trip device)
This was tried at 180MW load but
could not operate. Problem expected
24. ATT for HP/IP valves 28 19/06/08
in shutdown programme which was
attended.
GT R/Y/B , UT A/B Sprinkler system
25. 27 18/06/08
checked
26. UAT A/B Sprinkler system checked 27 18/06/08

DETAILS OF P&I CHECKS

CARRIED OUT

P&I CHECK STATUS

BOILER & TG SIDE
Actual Date Of Actual Date Of
Sl no Equipment Equipment
Check Check
• Area Boiler • Area TG
Boiler MFT & purge 17-06-08
1. 14/06/08 Unit Inter trip Check
permissive 18-06-08
2. ID Fan – A 15/06/08 Main Turbine Protection 17/06/08
3. ID Fan - B 15/06/08 CW pump-A 06/06/08
4. FD fan – A 09/06/08 CW pump-B 06/06/08
5. FD fan – B 10/06/08 ACW pump-A 06/06/08
6. PA fan – A 09/06/08 ACW pump-B 12/06/08
7. PA fan – B 10/06/08 ACW pump-C 12/06/08
8. SAPH – A 16/06/08 SGECW pump-A 06/06/08
9. SAPH - B 16/06/08 SGECW pump-B 06/06/08
10. PAPH – A 16/06/08 TGECW pump-A 05/06/08
11. PAPH - B 16/06/08 TGECW pump-B 06/06/08
12. BCW pump - A 09/06/08 TGECW pump-C 05/06/08
13. BCW pump – B 10/06/08 CEP-A 11/06/08
14. BCW pump - C 10/06/08 CEP-B 11/06/08
15. Mill - A 13/06/08 CEP-C 11/06/08
16. Mill - B 13/06/08 MDBFP-C 07/06/08
13/06/08&
17. Mill - C 13/06/08 TDBFP-A
16/06/08
18. Mill - D 13/06/08 TDBFP-B 16/06/08
19. Mill - E 13/06/08 Seal Oil System 17/06/08
20. Mill - F 13/06/08 Primary Water System 16/06/08
21. Mill- G 13/06/08 Control Fluid System 16/06/08
22. Mill- H 13/06/08 TG LO / Jacking System 17/06/08
23. Mill - J 13/06/08
24. Mill - K 13/06/08

ELECT SWGR / XFMR Battery &

Battery Chargers
OVERHAULING DETAILS

SWITCHGEARS OVERHAULING
Unit shut down Dt:23/05/08
SL. No of day Aft Normalization
DESCRIPTION Isolation
NO S/D date
• TG side SWGRS at 12.5 Mtr
1. SS Swgr – A 3 25/5/08 25/5/08
2. SSS – B 4 26/5/08 26/5/08
3. 3.3KV 6 UAA – A 4 26/5/08 26/5/08
4. 3.3KV 6UAA - B 6 28/5/08 28/5/08
5. Air Washer MCC 6 28/5/08 28/5/08
6. USS – A 7 29/5/08 29/5/08
7. UES 8 30/05/08 30/05/08
8. 11 KV 6 UB 8 30/5/08 30/5/08
9. SACDB Sec- A 9 31/05/08 31/5/08
10. SACDB Sec- B 9 31/05/08 31/5/08
11. USS – B 9 31/5/08 31/5/08
12. DCSVDB -12.5 9 31/5/08 31/5/08
13. TVDC 10 01/06/08 01/06/08
14. TMCC – B 11 02/6/08 02/6/08
15. TMCC – A 11 02/6/08 02/6/08
16. TURBINE ACDB 12 03/6/08 03/06/08
17. 11 KV 6UB 12 03/06/08 03/06/08
• SG side SWGRS at 26 Mtr
18. SB MCC – A & B 2 24/5/08 16/06/08
19. BOILER ACDB – A & B 2 24/5/08 24/5/08

20. COAL MILL MCC – A & B 4 26/5/08 26/5/08
21. BMCC – A 5 27/5/08 27/5/08
22. BDDC 5 27/5/08 27/5/08

SL. No of day Aft Normalization

DESCRIPTION Isolation
NO S/D date
23. BVDC 6 28/5/08 28/5/08
24. BMCC – B 8 30/5/08 30/5/08
• ESP/ASH handling SWGRS at
26 Mtr
25. ESP BOARD – A 2 24/5/08 03/06/08
26. ESP BOARD – B 2 24/5/08 03/06/08
27. ESP VFD ESP A/C MCC 9 31/5/08 02/06/08
28. ESP BOARD – C 14 05/06/08 07/06/08
29. ESP BOARD – D 14 05/06/08 07/06/08
30. BOTTOM ASH MCC– A & B 14 05/06/08 05/06/08
31. ASH EXTRACTION SWGR – B 13 04/06/08 09/06/08
32. ASH EXTRACTION SWGR – A 13 04/06/08 09/06/08
• Offsite SWGRS
33. CT MCC – 6B 2 24/05/08 28/05/08
34. CT MCC – 6A 9 31/05/08 05/06/08
35. CW( U# 5 & 6) MCC SEC # B 15 06/06/08 06/06/08
36. Boiler DCDB 27 M 15 06/06/08 06/06/08

TRANSFORMERS PM
SL. No of day aft
DESCRIPTION Isolation date Normalization Date
NO s/d
1. GTR/Y/B, UT-6A, UT-6B 2 24/05/08 18/06/08
2. UAT – 6A 4 26/05/08 26/05/08
3. UAT –6 B 6 28/05/08 28/5/08
4. ESP XFMR – A 4 26/05/08 05/06/08
5. ESP XFMR –B 4 26/05/08 05/06/08
6. ESP XFMR – C 14 05/06/08 07/06/08
7. ESP XFMR – D 14 05/06/08 07/06/08
8. UST – A 7 29/05/08 29/05/08
9. UST - B 8 31/05/08 31/05/08
10. SST - A 2 25/05/08 25/05/08
11. SST – B 3 26/05/08 26/05/08
12. AET – A 13 05/06/08 05/06/08
13. AET - B 13 05/06/08 05/06/08
OFF SITE XFMRS
14. CT XFMR - A 8 31/05/08 05/06/08
15. CT XFMR - B 1 24/05/08 28/05/08
16. CT XFMR - C 8 31/05/08 05/06/08

Details Battery/ Battery Charger Overhauling

Sl.N
Description Battery Set Isolation Normalization
o
1. 220V DC Charger - 1 1 23/05/08 26/5/08
2. 220 V DC Charger - 2 2 26/5/08 29/5/08
3. UPS – 1 Charger - 1
04/06/08 06/06/08
04/06/08 06/06/08
4. UPS – 2 Charger - 2
1
5. TG Charger - 1 24/05/08
26/05/08
30/05/08
6. TG Charger - 2 2 28/05/08
7. TG Charger - 3
8. TG Charger - 4
9. SG Charger - 1
23/05/08 27/05/08
28/05/08 30/05/08
10. SG Charger - 2
11. SG Charger - 3
12. SG Charger - 4
13. 24 V C&I Ch – 1 23/05/08 26/05/08
14. 24 V C&I Ch – 2 26/05/08 27/05/08
15. UPS by C&I 4/06/08 06/06/08

MAJOR PENDING JOBS AFTER

OVERHAULING

MAJOR PENDING JOBS AFTER OVERHAULING

Sl Present
Responsibility
no Status
• SG Area
1. ESP FB-1( towards ID fan) not available .( spare problem ) DGM ( AHD) Attended
2. Hot PA damper not responding properly in many mills . DGM (C&I / BMD) Attended
3. BOF damper LHS (1) Gear box /Actuator not available DGM (EMD)
ID Fan –A out let gate – 1 is not operating . In open position
4. DGM (EMD) Attended
kept in track mode
SAPH- A abnormal sound from FC/Motor , yet to be
5. DGM ( BMD) Attended
ascertained
6. ESP fields tripping frequently . DGM ( AHD) Attended
• TG Area
ACW/SGECW/TGECW/MDBFP-C all pump suction valve LS
7. DGM (C&I )
kept bypassed
Problem experienced with OS Test Motor Module . To be
8. DGM (EMDI ) attended
checked .
LPBP fast opening(45% for 3 Sec) given during TG trip
9. condition
DGM (C&I )
LPBP opening logic modification done with installation of
10. three additional transmitteer.
DGM (TMD/C&I )
11. HPCV 1 &2 operation mismatch 100 / 50 % DGM (TMD)
12. LPBP – CV 1 erratic behavior DGM (TMD) attended
13. Condensate system valve passing still 230 T/Hour DGM (TMD) attended
H2 leakage is more 2 - 3 cyl /day against acceptable limit of
14. DGM (EMD)
½ cyl. / day
ACW self cleaning strainer – B ( towards # 7 ) is mech jam ,
15. DGM (TMD)
Attended during O/H still problem persist .
M.S. Header drain MS 417/419 drain valve are manual valve
16. DGM (TMD /EMD)
, No actuator available
17. HRH109 valve is having problem DGM (TMD) attended
18. TDBFP – B vibration at 400 RPM going high > 75 mm DGM (TMD) Attended
CW Pump inlet duct ARV manual valve at GT Yard is under
19. DGM ( OFFsite )
ground
20. DC Local control panel P/S indication not available DGM (EMD)
21. TDBFP CRH / Aux. St . ACV – A problem DGM (TMD) Attended
22. Following approach problems are still persisting
D/A stand pipe DGM (TMD)
ACW self cleaning strainer v/v DGM (TMD)
Bunker O/L gate DGM (BMD)

DETAILS OF MAJOR
ACTIVITIES

Details of TG Set Barring Gear Stopping Activities.
Sl no Activity Date Time Remarks

HP Casing Temp – 440/448ºC
1. Unit Trip Out Time 23/05/08 14:00 hrs HP Shaft Temp - 448ºC
IP Shaft temp – 442ºC
2. HP casing Temp Reached 300 0 C 25/05/08 18:00 hrs
HP Casing Temp - 294/294ºC
3. Vacuum Killed 25/05/08 18:45 hrs HP Shaft Temp - 306/308ºC
IP Shaft temp- 245/246ºC
4. Force Cooling of TG Set Started 26/05/08 01:10 hrs After all readiness & TMD clearance.
HPC -130/131ºC,
HPS -118/119ºC
HP casing/shaft Temp Reached 120 0
5. 28/05/08 11:20 hrs IPS - 118/119ºC
C.
IPC - F - 151/114
IPC - R– 145/117
6. TG barring gear stopped at 28/05/08 11:20 hrs For dismantling the excitation system.
Total Duration For Stopping the TG
7. 117 hrs
Barring Gear after Unit Shut Down
Only JOP kept in service for turbine
8. TG Lub Oil system stopped at 28/05/08 12:10 hrs
work.
Total Duration For Stopping the TG
9. Lub Oil system after Unit Shut 118 hrs
Down
Turbine Brng metal temp Rise after Lub oil system stopped at
Maximum Casing Temp of 150 ºC & Shaft temp of 130 ºC
( Only JOP Kept in service)
Time HPF HPR TB IPR LPR EXCITER

TE EE
BEARING 1 2 2 3 4 5 6 7
10:30 46 46 46 47 47 46 47 45
11:40 45 45 44 46 46 45 47 45
12:10 45 44 44 45 45 44 47 45
12:50 46 45 49 45 44 44 48 43
13:20 47 46 50 47 45 43 48 43
13:35 48 47 51 47 45 43 48 42
14:15 48 47 52 44 44 42 48 42
14:30 49 49 52 49 44 42 48 42
15:30 49 50 54 50 44 41 46 42
16:50 50 52 57 51 46 40 48 43
20:45 52 57 62 44 43 40 48 58
22:30 52 59 64 43 43 39 48 58
03:00 50 61 49 42 40 34 44 58
06:00 48 61 49 42 39 33 44 57
07:00 49 61 49 41 39 34 44 57
10:00 37 61 49 41 39 46 48 57

Turbine Max metal temp after Lub oil system stopped

(Only JOP in service)
HPC HPS IPS HPC IPC IPC IP DT

Time
100 % /50 % 100 % /50 % 100 % /50 % Top/Bot Top/Bot Top/Bot F/R
28/05/08
14:00 122/122 115/115 128/129 122/111 151/114 145/117
15:40 121121 114/114 127/128 121/110 151/114 144/116
16:50 119/119 112/113 125/126 118/118 149/111 143/114
20:45 113/113 109/109 122/122 113/104 146/107 139/108
22:30 111/111 107/107 120/120 111/103 145/104 139/107
29/05/08
03:00 106/106 103/104 116/116 106/100 141/100 135/101
06:00 104/104 101/101 114/114 104/98 139/97 134/99
07:00 103/103 101/101 113/113 104/97 139/96 133/98
10:40 101/101 98/99 110/110 101/96 137/93 131/95 43/35

Details of H2 purge out with CO2
Sl no DESCRIPTION DATE TIME REMARKS
• CLEARANCE FOR H2
DEPRESSURISATION
1. Clearance Given by EMD 24/05/08 17:00 YES
• H2 DEPRESSURISATION
2. Start of depressurisation 24/05/08 17:40
3. Depressurised to 0.5 ksc 24/05/08 18:10
• PURGING WITH CO2
4. Start of CO2 filling & purging 24/05/08 18:10
Total 58 cylinders
5. Completion of CO2 filling & purging 25/05/08 08:00
consumed
6. CO2 purity in H2 25/05/08 08:00 98%
7. Clearance by Chemist for air filling 25/05/08 08:00 YES
8. Total Cylinders Consumed 25/05/08 08:00 58 nos
• PURGING WITH AIR
9. Start of air Purging 25/05/08 08:30
10. Air Purging completed 26/05/08 00:30
11. Clearance by Chemist 26/05/08 00:30 CO2 in air 0.3%
Air purging started at
12. Air pressure 1,0 ksc 26/05/08 01:00
0.5 ksc
After 24 hrs of air
13. Air pressure 3.0ksc 26/05/08 purging the pr raised to
3.0 ksc
NB : Some of the CO2 cylinders were having less pressure , so the no of cylinders
consumed were more . (Normally 45 cylinders)

DETAILS OF H2 FILLING IN GENERATOR
AFTER Unit Annual Overhaul
Sl no Description Date Time REMARKS

• CLEARANCE FOR PURGING
OF AIR WITH CO2
1. Clearance BY EMD/TMD /C&I 17/06/08 03:00 After leakage checking
• PURGING OF AIR WITH CO2

2. Start of CO2 filling & air purging 17/06/08 03:00
3. Completion of CO2 filling & air purging 17/06/08 15:30 12:30hrs
4. CO2 purity in air By Chemist / Remote 17/06/08 15:30 98%
5. Clearance By Chemist 17/06/08 15:30
6. Total Cylinders Consumed 17/06/08 15:30 55
• CLEARANCE FOR FILLING OF
H2
7. Start of filing of H2 & purging of CO2 17/06/08 16:00
8. H2 purity 98 % reached at 18/06/08 02:30
9. Clearance by Chemist 18/06/08 02:30
10. No of H2 cylinders consumed up to 98 % 18/06/08 02:30 82 cylinders
11. H2 pressurisation started 18/06/08 02:30
12. H2 pressure 3.3 ksc reached at 18/06/08 05:00 Pr up to 3.32ksc
No of H2 cylinders consumed for
13. 18/06/08 05:00 57 cylinders
pressurisation
Total H2 cylinders Consumed in the
14. 18/06/08 139 cylinders
process
NB : The air purging with CO2 & CO2 purge out with H2 , H2 presurisation carried out
with the TG set at stand still . Barring gear Finally put into service at 2 :45

GENERATOR AIR TIGHTNESS TEST ( 1st time)

AFTER Unit Annual Overhaul
Sl
Description Date Time REMARKS
no
CLEARANCE FOR AIR FILLING
1. Clearance BY EMD/TMD /C&I 14/06/2008 00:10 hrs
Commencement of air Filling / After Seal oil system was started
2. 14/06/2008 00:40 hrs
pressurisation at 19:58 hrs
Generator opened , hence air
3. Air Pressure Reached 4.00 ksc 14/06/2008 00:40 hrs
pressure raised to 4.0 ksc .
4. H2 Coolers Kept isolated 14/06/2008 Yes , kept isolated
5. Air Leak test Started 14/06/2008 2:30 hrs After all parameters stabilized
6. Depressurized 14/06/2008 5:45 hrs To arrest leakages
Commencement of air Filling /
7. 14/06/2008 11:05
pressurisation
8. Air Pressure Reached 4.00 ksc 14/06/2008 12:57 Pressure reached 3.94 ksc
9. Air Leak test Started 14/06/2008 13:00 hrs
10. 15/06/2008 10:00 hrs Pressure 3.72 ksc
11. Depressurized 15/06/2008 10:24 hrs
Commencement of air Filling /
12. 15/06/2008 15:59 hrs
pressurisation
13. Air Pressure Reached 4.00 ksc 15/06/2008 17:58 hrs
14. Air Leak test Started 15/06/2008 18:00 hrs Air Pressure 3.93
15. 16/06/2008 9:00 hrs Air Pressure 3.73
16. Pressure Drop in 15 Hrs 0.20 ksc Loss = 13.792 M3 in 24 hrs
= 0.06 ksc ( 3.46-3.40)
17. Pr Drop is 1st 24 Hrs Air Leakage Quantity for 24 hrs =
4.9569 m3
= 0.05 ksc ( 3.40-3.35)
18. Pr Drop is 2nd 24 Hrs Air Leakage Quantity for 48 hrs =
3.879 m3
= 0.07 ksc ( 3.35-3.28)
19. Pr Drop is 3rd 24 Hrs Air Leakage Quantity for 72 hrs =
3.527 m3

CONDENSER FLOOD TEST DETAILS
Sl
Activity Date Time Remarks
no
Clearance BY TMD after All Line up took time 26 minutes
1. 08/06/08 16:04 hrs
readiness
-Through normal make up by running
DM makeup Pump.
2. Condenser Filling 08/06/08 16:30 hrs -By running CST Pump
-By running boiler fill pump to D/A to
LPDFT through D/A over flow line.
Total filling Time 3:00 Minutes
Water Level Up to Bottom
3. 08/06/08 19:30 hrs PVC Tube was connected to LPH
of LPT Deck
Vent up to 17 Mtr
Checking of water box for any tube
Checking BY Joint Group
4. 08/06/08 19:30 hrs leakage was carried out jointly.
Oprn /TMD/EEMG
Leakage points were recorded.
10:00 Normal level as TG side work
5. Hot well draining 08/06/08 20:30 hrs
was under progress .
Condenser Water Box
6. 9/06/08 18:00 hrs Water Box Charged
charging Clearance
CW pump – B started for TMD
7. CW Pump Started 10/06/08 10:30 hrs
Requirement

BOILER HYDRO TEST 1ST TIME (INTERNAL)
Sl
no
Clearance For Boiler Filling
1. 11/06/08
by BMD
2. Boiler Filling started 11/06/08 11:00
3. Boiler Filling Completed 11/06/08 13:10
4. MD BFP Started 11/06/08 13:40
Boiler Pressure reached
5. 11/06/08 14:52
150 Ksc
6. Pressure Reduction started 11/06/08
Internal Inspection carried
7. 11/06/08
Out at 80-100 ksc
8. MDBFP stopped 11/06/08 17:16
Total Duration For MD
9. 11/06/08 3hrs 31min
BFP Running
BOILER HYDRO TEST 2ND TIME (EXTERNAL)
Sl
no
Clearance For Boiler Filling
1. 12/06/08 07:30
by BMD
2. Boiler Filled 12/06/08 08:00
3. MD BFP Started 12/06/08 09:26
4. 12/06/08
200 Ksc
5. 12/06/08
259 Ksc
6. Pressure Reduction started 12/06/08
Internal Inspection carried
7. 12/06/08
Out at 80-100 ksc
8. MDBFP stopped 12/06/08 13:40
Total Duration For MD
9. 12/06/08 4hrs 14min
BFP Running

TOTAL MDBFP RUNNING FOR HYDROTEST
1. 1st Internal Hydro 3hrs 31min

Total 7 hrs 45min
2. External Hydro 4hrs 14min
• MDBFP – C PARAMETERS ( FINAL HYDRO )
Time Unit 10:20 Hrs 11:39 Hrs 12:00 Hrs

Suc Flow T/Hr 365 371 523
Suction Temp 0C 63 71 74.6
Drum pressure Ksc 145 154 264.4
Discharge pressure Ksc 140 149.4 259.87
Pump Current Amp 242 252 374
Max Bearing temp 0C 73/T13 73.5 78.2
Max thrust Bearing temp 0C 75/T25 76.2 89.33
Scoop Position % 43.75 48.0 69.50
LLCV position % 60% 60% 100%

Details of MOT Draining & Refilling
Sl
no
Before Unit Shutdown , Joint
1. COT Readiness Checked Yes
inspection carried out
After Unit Shutdown Joint inspection
2. DOT readiness Checked Yes
carried out.
Before Unit Shut down (Check
3. COPU availability Checked Yes protection system is working, Lights in
COT/DOT room adequate)
HPC – 122/122 0 C
4. TG Lub Oil system stopped 28/05/08 11:30 HPS - 115/115 0 C
IPS - 128/129 0 C
Air locking was experienced , it was
5. MOT Draining started to DOT 02/06/08 19:00
released , then the Flow started .
Oil transferred from DOT to
6. 03/06/08 09:15 Completed
COT through COPU
MOT Room Deluge valve
7. 03/06/08 13:45 Dirty Oil Tank Overflow took place
Operation carried Out
MOT Final Inspection after
8. 03/06/08 19:00 Joint Inspection with chemistry.
cleaning
Through clean Oil Pump , Completed
Oil Transfer From COT to MOT at Hrs , Further Oil Topped
9. 04/06/08 10:00
through CO Pump started up through the Leakage Oil Pump
from Barrels .
10. Final MOT Oil Level 04/06/08 17:40 + 406 mm in Local

DETAILS OF BOILER SAFETY VALVE FLOATING
Sl
no
Boiler Pressure Raising started
1. 17/06/08 21:42
after Electrical testing completed
2. Boiler Pressure reached 160 ksc 18/06/08 00:45 Rate of Pressure Rise 40 ksc /Hr
All 8 valves trevy setting was done
3. Trevy setting completion 18/06/08
6 drum + 2 MS
Clearance for Further pressure
4. 18/06/08 03:30
raising & Valve Floating
Pressure raised & 1st time SV- SV-8 (RHS) actually floated. Operated
5. 18/06/08 03:38
8 Floating Tried at 186.02 ksc and reset at 183 ksc
6. 2nd time Floating Tried 18/06/08
Pressure Reduction clearance After 1hr of BMD clearance, pressure
7. 18/06/08 03:33
Given by Boiler Maintenance reached to 65 ksc at 04:33 hrs
Oil Guns in service & Oil

1. 11 Oil pressure 8.5 ksc
Pressure
2. Mills in service & Coal Flow 1 35
3. HP BP Opening 35/35
After Safety valve Floating
Immediately the HP BP to be
4. LPBP Opening 45/45 opened to reduce the pressure .
LPBP to be kept on auto at Less
Fixed Pressure .
5. MS / HRH temp 409/421 HRH Pr 6.5 ksc
NB : During SV Floating Boiler FW Flow to be maintained even though the level goes HI (
which is not actual ) .
For Drum safety valve FW Flow around 900-1000 tons/Hr , MS Safety Valve 700-800 T/ Hr .

Furnace Pressurization Test Details 1st Time

Before Overhaul Commencement
Date: 23/06/2008
Sl
no
Unit Tripped & MFT took
1. 23/06/08 14:00 hrs
place at
Both Set ID/FD fan kept in
2. 23/06/08 I/S Yes
service
3. Air Flow maintained 23/06/08 16:52 hrs 834 T/Hr
Pressurised up to 124mmwc By
Fur Pressurized to 120
4. 23/06/08 16:52 hrs throttling the FG dampers at APH
MMWC
Outlet
ID /FD Fan stopped at 19:38 Hrs as
5. Pressure Reduced 23/06/08 18:00
temp has dropped to 150 0 C
Major Leakages Identified are as follows

• Wind box bottom Corner 1,2,3 &4
• Wind box Top Corner 2&4
• Pent house corner-1 insulation damaged
Furnace Pressurization Test Details 2nd Time

After Overhaul
Date: 17/06/2008
Sl
no
1. All Clearances obtained at 16/06/08 23:30hrs
ESP inlet all gates are closed to
2. Only FD Fan Kept in service 17/06/08 00:10hrs
check the passing .
3. Fur Pressurized to70 MWC 17/06/08
PA Duct Pressurization to 800 mm
4. Pressure Reduced 17/06/08 06:54 hrs
carried out after PA Fan running

OTHER PARAMETERS DURING

OVERHAULING

Boiler Cooling Down Parameters
Time of Boiler Tripped :- At 14:00 Hrs on 23/05/08

AIR AIR
FG I/L FG I/L BCW A BCW B BCW C MAX.DR
DRUM FURN O/L O/L BCW BCW BCW MAX.DRUM MAX.DRU
TOTAL TEMP. TEMP. MTR MTR MTR UM
Date Time PRESS ACE TEMP. TEMP. SUC.M SUC.M SUC.M METAL M METAL
AIR SAPH SAPH CURR CURR CURR METAL
. DRAFT SAPH SAPH AN.B AN.C AN.A TEMP(L) TEMP(R)
A B ENT ENT ENT TEMP(M)
A B
5/24/2008 13:00:00 0 65.55 -1.07 45.85 42.35 54.65 51.6 0 0 0 84.2 79.52 80.12 100.24 99.9 100.7
5/24/2008 12:00:00 0 65.55 -11.78 46.15 44.65 55.9 52.75 0.02 0 0.02 85.8 79.76 86.44 99.68 99.05 99.95
5/24/2008 11:00:00 0 66 -13.17 46.95 48.1 59.35 58.75 0.01 0.03 0.03 87.32 84.76 86.84 97.96 97.1 98
5/24/2008 10:00:00 0.03 66 -12.95 50.45 54.25 62.7 63.5 0.01 0.03 0.03 86.24 86.6 87.32 96.8 96.4 97.05
5/24/2008 9:00:00 0.05 65.85 -14.93 56 58.9 65.6 66.15 0.01 0.03 0.03 87.16 87.76 88.36 95.72 95.9 96.45
5/24/2008 8:00:00 0.08 65.4 -14.21 61.6 62.65 69.4 69.8 0.01 0.03 0.03 88.52 88 90.16 94.68 94.85 95.35
5/24/2008 7:00:00 0.1 64.95 -13.31 68.9 70.4 73.95 74.2 0.01 0.03 0.03 90.36 88.96 90.72 93.08 92.8 93.05
5/24/2008 6:00:00 0.1 64.35 -10.34 78 79.45 79.4 79.15 0.01 0.03 0.03 90.84 89.52 93.28 91.76 91 91.65
5/24/2008 5:00:00 0.1 63.6 5.46 86.9 90.8 84.65 83.7 30.18 0.03 52.1 93.8 92.2 97.32 94.24 93.95 94.65
5/24/2008 4:00:00 0.15 62.85 6.14 91.35 100.35 89.25 87.25 73.94 0.03 74.35 97.84 97.12 100.72 97.84 97.15 97.85
5/24/2008 3:00:00 0.3 62.1 7.26 94.45 104.15 92.9 89.2 74.66 0.03 75.07 101.12 100.56 104.8 101.64 100.65 101.5
5/24/2008 2:00:00 0.53 61.5 8.07 97.4 108.05 96.15 87.6 74.32 0.03 74.8 105.08 104.84 110 106.08 105.1 105.5
5/24/2008 1:00:00 0.83 60.75 9.11 100 111.7 97.05 77.85 75.53 51.08 76.26 110.36 110.32 116.08 111.8 110.6 111.3
5/24/2008 0:00:00 1.28 60.15 9.56 100.75 115.95 103.3 85.9 75.85 75.57 76.73 116.44 116.76 123.6 119.12 118.25 118.45

AIR AIR
FG I/L FG I/L BCW A BCW B BCW C MAX.DR
DRUM FURN O/L O/L BCW BCW BCW MAX.DRUM MAX.DRU
TOTAL TEMP. TEMP. MTR MTR MTR UM
Date Time PRESS ACE TEMP. TEMP. SUC.M SUC.M SUC.M METAL M METAL
AIR SAPH SAPH CURR CURR CURR METAL
. DRAFT SAPH SAPH AN.B AN.C AN.A TEMP(L) TEMP(R)
A B ENT ENT ENT TEMP(M)
A B
5/23/2008 23:00:00 1.95 59.7 9.92 104.8 123.15 111.9 101.05 74.79 74.5 75.49 123.92 124.44 132.92 128.12 127.15 127.7
5/23/2008 22:00:00 2.98 59.4 10.64 80.65 131.5 123.4 123.25 73.39 72.96 74.12 133.2 133.8 143.36 138.4 137.2 137.6
5/23/2008 21:00:00 4.13 59.1 12.89 105.9 141.25 131.3 129.9 72.88 72.46 73.54 143.84 144.36 153 148.68 147.1 148.05
5/23/2008 20:00:00 5.93 58.8 -5.25 152.8 149.95 139.35 139.05 71.9 71.5 72.61 153.28 153.92 165.48 158.4 157.15 157.6
5/23/2008 19:00:00 9.88 355.2 -28.7 150.9 150.55 140.55 139.95 70.73 70.18 71.29 165.72 166.36 184.88 173.56 173.15 173.2
5/23/2008 18:00:00 16.53 861 117.02 168.15 168.95 133.55 150 70.38 70.1 71.16 185.04 185.52 207.32 194.76 194.3 194.75
5/23/2008 17:00:00 27.13 866.1 3.53 191.9 189.75 90.3 167.7 69.09 68.62 69.7 207.32 207.56 232.32 219.76 218.8 219.3
5/23/2008 16:00:00 44.65 953.4 -16.23 205.3 206.15 181.7 179.85 67.3 66.74 67.81 232.24 232.48 261.16 247.28 246.95 247.35
5/23/2008 15:00:00 83.25 964.05 -10.25 240.35 242 214.85 212.65 65.13 64.68 65.66 260.64 260.84 302.04 282.72 282.6 282.8
Unit Stopped 14:00 hrs

5/23/2008 14:00:00 132 1095.91 -9.8 285.1 287.8 257.35 255.8 61.01 57.33 61.61 301.84 301.68 331.84 322.6 321.95 322.25
5/23/2008 13:00:00 138.85 1274.3 -10.11 338.8 337.2 296.15 295.25 56.24 55.29 56.71 332.52 332 333.64 337.24 335.9 336.55
5/23/2008 12:00:00 138.2 1330.23 -10.02 343.3 340.6 301.3 300.65 55.94 54.99 56.28 335.24 333.88 335.2 338.32 336.9 337.25
5/23/2008 11:00:00 173.33 1541.17 -9.66 351.7 349.15 312.2 312.95 55.81 55.01 56.14 336.48 335.08 349.92 347.32 346 346.65
5/23/2008 10:00:00 193.48 1840.16 -9.84 375.9 372.2 329.25 330.9 52.81 52.48 52.88 352.88 350.56 355.16 357.08 355.9 356.7
5/23/2008 9:00:00 185.45 1752.28 -9.53 378.75 373.6 333.3 334.2 51.6 50.53 51.52 358.8 356.12 353.72 357 355.45 356.65
5/23/2008 8:00:00 186.7 1827.45 -9.93 375.4 369.65 325.75 326 52.04 51.39 52.06 356.64 353.96 354.2 355.48 353.95 354.65
Boiler drained at : - 24/05/08 11:30 Hrs

Turbine Cooling Down Parameters
Unit Stopped at 14:00 Hrs on 23-05-08 for Annual Overhaul Force Cooling started at 1:10 hrs on 26-05-08
Without carrying the actual OS test as LPT OH was planned TG barring gear stopped at Hrs on 28-05-08 at 11:20 Hrs
Total time to stop barring gear = 117 Hrs
HPCASIN
OVEALL OVEALL RELATIVE RELATIVE HPSHAFT IP SHAFT HPSV HPCV
RELATIVE AXIAL G
Date TIME SPEED VACUUM EXP EXP EXP EXP IN/OUT IN/OUT IN/OUT IN/OUT
EXP SHIFT IN/OUT
HP(MM) IP(MM) HP(MM IP(MM TEMP TEMP TEMP TEMP
TEMP
2605/08 23:07 73.8 -0.00 9.93 8.41 -0.31 1.34 11.81- -0.23 286/286 297/299 237/239 239/237 244/244
00:04 73.8 -0.00 9.85 8.30 -0.31 1.33 11.56 -0.23 284/284 295/297 235/236 236/234 244/244
2705/08 01:14 73.79 -0.00 9.75 8.02 -0.41 1.28 10.86 -0.22 293/283 293/294 233/234 233/231 237/238
2:20 80.91 -0.31 9.63 7.75 -0.69 1.22 10.21 -0.20 281/281 287/289 231/232 229/227 207/212
3:20 80.91 -0.30 9.50 7.55 -0.97 1.15 16.05 -0.18 279/278 281/284 230/229 225/226 185/189
4:30 74.82 -0.29 9.32 7.32 -1.28 1.10 15.38 -0.17 275/274 278/274 228/227 220/222 169/165
5:30 73.79 -0.29 9.24 7.23 -1.40 1.10 14.84 -0.17 273/272 275/277 227/226 218/220 161/158
6:30 73.79 -0.28 9.08 7.09 -1.57 1.08 14.58 -0.17 270/267 270/269 225/224 215/217 150/147
9:40 73 -0.29 8.8 6.8 -2.0 0.98 13.4 -0.16 256/257 251/255 217/219 205/203 122/123
11:00 76 -0.28 8.28 6.65 -2.12 0.95 13.10 -0.16 250/252 245/248 215/216 200/199 114/116
13:00 73.8 -0.29 7.93 6.48 -2.24 0.88 12.64 -0.16 243/244 235/238 210/212 193/191 105/107
14:00 71.08 -0.05 7.70 6.38 -2.24 0.82 12.24 -0.16 238/237 231/229 209/208 186/188 104/103
15:00 67.35 -0.10 7.59 6.31 -2.10 0.86 12.30 -0.16 234/235 230/231 207/208 185/184 106/106
16:00 74.15 -0.29 7.43 6.27 -2.01 0.82 12.05 -0.17 230/231 225/227 204/205 182/181 105/106
17:00 73.79 -0.28 7.27 6.19 -1.88 0.81 11.75 -0.16 226/226 226/227 202/203 199/177 109/109

HPCASIN
RELATIVE AXIAL G
EXP SHIFT IN/OUT
TEMP
18:30 73.79 0.7 7.09 6.06 -1.70 0.71 11.38 -0.17 224/225 223/225 199/200 174/173 113/113
21:00 73.79 -0.27 6.81 5.88 -1.39 0.59 10.89 -0.15 216/217 216/218 194/195 167/166 114/114
22:00 73.79 -0.27 6.72 5.80 -1.29 0.57 10.67 -0.16 212/212 212/215 192/194 165/164 114/114
00:00 73.23 -0.27 6.40 5.61 -1.02 0.47 10.09 -0.15 205/205 207/207 188/188 161/160 113/113
02:30 73.23 -0.27 6.30 5.49 -0.88 0.43 9.78 -0.15 201/202 202/202 185/185 158/185 112/112
04:30 73.13 -0.27 6.06 5.36 -0.74 0.39 9.47 -0.14 196/196 197/195 181/180 153/154 111/111
09:50 74.13 -0.27 5.66 5.06 -0.48 0.28 8.86 -0.15 185/185 184/185 170/171 144/147 108/108
11:50 76 -0.42 5.55 4.89 -0.43 0.20 8.37 -0.14 181/181 180/181 166/168 140/139 107/107
12:50 77 -0.42 5.45 4.83 -0.40 0.17 8.12 -0.15 179/179 178/180 166/166 138/137 107/107
13:30 80 -0.50 5.42 4.77 -0.37 0.13 8.06 -0.14 177/179 178/179 165/165 137/136 106/106
15:30 78.88 -0.47 5.28 4.67 -0.35 0.05 7.75 -0.14 175/175 174/`175 162/163 134/133 105/105
16:30 73.79 -0.47 5.22 4.67 -0.33 0.04 7.63 -0.13 173/174 172/174 160/161 132/131 105/105
17:30 78 -0.49 5.10 4.57 -0.44 0 7.54 -0.14 172/172 168/170 159/159 130/129 95/96
17:90 76.5 -0.49 5.09 4.56 -0.48 7.41 -0.14 171/172 166/169 158/159 129/128 93/94
18:20 80.95 -0.41 5.03 4.54 -0.55 -0.03 7.38 -0.14 170/171 165/167 157/158 119/118 88/90
23:40 73.79 -0.25 4.49 4.34 -1.43 -0.07 6.86 -0.14 159/160 147/149 149/150 116/115 61/63
28/5/08 00:40 73.79 -0.27 4.31 4.29 -1.54 -0.07 6.71 -0.15 155/156 142/144 147/149 116/115 59/60
1:40 73.79 -0.26 4.27 4.27 -1.56 -0.09 6.64 -0.14 154/155 141/143 146/147 115/114 58/59
2:40 73.79 -0.25 4.42 4.23 -1.59 -0.11 6.52 -0.14 150/151 137/139 144/145 112/112 56/57

HPCASIN
RELATIVE AXIAL G
EXP SHIFT IN/OUT
TEMP
5:40 73.79 -0.25 3.87 4.14 -1.60 -0.11 6.31 -0.14 144/145 130/132 140/142 108/107 52/54
6:40 73.79 -0.25 3.76 4.11 -1.60 -0.12 6.27 -0.14 141/142 126/129 139/140 106/105 52/52
9:40 69 -0.33 3.45 3.99 -1.47 0.17 5.97 0.12 133/134 120/121 135/136 100/99 50/50
11:15 129/130 119/120 133/133 97/97 53/53
12:50 3.22 3.89 -1.15 -0.18 5.69 -0.15 125/126 125/126 131/132 95/94 55/55
13:20 3.2 3.88 -1.07 -0.15 5.69 -0.16 124/125 124/125 130/131 94/93 56/56

Turbine Cooling Down Other Parameters

Seal Steam Leak off Seal steam HPBP Down HPT Top/Bot IPT Top/Bot
Date Time LP Exh.Temp.
Pr/Temp V/V % V/V % Temp. Temp. Temp.
12:01 250/271 4.5% 99% 84 68/68 364/339 318/276
14:00 252/262 4.44 92 92 65/66 360/335 312/272
15:00 254/208 4.39 88% 95 64/65 357/332 308/271
24/5/08 22:40 251/266 4.29 81% 94 59/59 339/314 289/256
25/5/08 18:03 254/255 4.29 79% 104 45/46 296/272 258/231
20:30 0/174 10.44 0% 93 45/46 291/267 254/223
25/5/08 23:06 0/112 10.25 0% 82 47/48 286/262 251/217

0/98 10.35 0% 80 46/47 285/261 250/215
26/5/08 01:12 0/92 10.15 0% 76 45/46 283/260 248213
2:20 0/86 10.35 0% 73 45/47 281/257 247/211
3:20 0/80 10.30 0% 71 43/45 278/255 245/280
3:30 0/73 10.4 0% 69 44/45 274/252 243/201
5:30 0/70 10.18 0% 68 43/45 272/280 243/201
6:30 0/67 10.54 0% 66 43/45 269/248 243/206
21:00 0/45 10.49 0% 56 42/43 216/200 204/204
205/178
27/05/08 18:30 0/40 5.71% 0% 47 38/39 174/160 179/144
00:00 0/40 10.59 0% 55.88 41.00 208/193 210/172
02:30 0/40 10.59 0% 54.40 40.00 209/187 206/168
04:30 0/40 10.59 0% 52.7 40.00 198/183 202/164
28/5/08 9:40 42 C 134/121 157/122

151/125

Unit Parameters Before &

After Annual Overhaul.

COMPARATIVE PARAMETERS BEFORE & AFTER ANNUAL OH

Area – SG
Before O/H After OH
Sl no Description of the parameters Unit
20-05-08 25-06-08
1. GEN # 6 MW MW 500.77 505.88
2. GEN # 6 FREQ Hz 49.69 49.16
3. FD FAN A DIS PR mmwcl 179.45 196.62
4. FD FAN B DIS PR mmwcl 176.90 194.55
5. ID FAN A DIS PR mmwcl 134.64 122.16
6. ID FAN B DIS PR mmwcl 138.09 127.98
7. PA FAN A DIS PR mmwcl 857.02 859.47
8. PA FAN B DIS PR mmwcl 861.18 858.22
9. PA HDR PRESSURE mmwcl 821.30 819.18
10. FURNANCE DRAFT mmwcl -9.21 -11.27
11. WIND BOX PR.(LHS) mmwcl 66.61 80.18
12. WIND BOX PR.(RHS) mmwcl 67.18 79.07
13. O2 VALUE OF FG % 2.90 3.50
14. O2 VALUE OF FG % 2.69 2.53
15. CO VALUE % 43.74 37.61
16. CHIMNEY I/L (NOx) ANAL mg/m3 290.32 297.59
17. CHIMNEY I/L (SOx) ANAL mg/m3 630.55 746.10
18. CHIMNEY I/L (OPA.) ANAL mg/nm3 35.34 59.13
19. CHIMNEY I/L (CO) ANAL % 43.74 37.61
20. BOILER LOAD INDEX % 85.49 93.60
21. COAL CONSUMPTION-DAY PREV. Tons 9252.18 0
22. TOTAL COAL FLOW TPH 380.88 386.22
23. TOTAL AIR FLOW TPH 1764.17 1843.88
24. TOTAL PRIMARY AIR FLOW TPH 702.61 646.44
25. SECONDARY AIR FLOW-L TPH 549.49 610.55
26. SECONDARY AIR FLOW-R TPH 511.64 586.76
27. LTSH (EL-01/AY-23)TEMP Deg C 426.48 408.53
28. SH DIV. PNL TUBES TMP-GS Deg C 0 0
29. SH DIV. PNL TUBES TMP-GS Deg C 516.41 481.52
32. PLTN-SH(EL-02/AY-15)TEMP Deg C 527.35 525.20
33. PLTN-SH(EL-02/AY-15)TEMP Deg C 538.49 519.01
34. RH HDR(EL-01/AY-66)TEMP Deg C 540.07 577.37

Before O/H After OH

20-05-08 25-06-08
38. SRAPH-A I/L TEMP Deg C 36.02 29.90
39. SRAPH-B I/L TEMP Deg C 38.43 32.65
40. PRAPH-A I/L TEMP Deg C 44.19 38.17
41. PRAPH-B I/L TEMP Deg C 44.12 38.70
42. SAHA AIR O/L TEMP Deg C 337.42 310.78
43. SAHB AIR O/L TEMP Deg C 341.64 313.64
44. PAHA AIR O/L TEMP Deg C 337.06 315.39
45. PAHB AIR O/L TEMP Deg C 323.57 311.84
46. FURNACE TEMP, accoustic Deg C 8.57 1040.99
47. FG TMP AT I/L PLTN SH-L Deg C 856.72 805.14
48. FG TMP AT O/L PLTN SH-L Deg C 861.85 811.15
49. FG TMP AT O/L RH-L Deg C 689.59 652.56
50. FG TMP AT O/L HOR SH-L Deg C 484.65 468.59
51. FG TMP AT O/L ECO 1&2-L Deg C 371.85 364.56
52. FG TMP AT O/L ECO 3-L Deg C 344.56 347.75
53. FG TMP AT I/L PLTN SH -R Deg C 722.56 739.50
54. FG TMP AT O/L PLTN SH-R Deg C 802.88 859.89
55. FG TMP AT O/L RH-R Deg C 714.40 716.95
56. FG TMP AT O/L HOR SH-R Deg C 511.47 495.11
57. FG TMP AT O/L ECO1&2 -R Deg C 388.92 369.47
58. FG TMP AT O/L ECO 3-R Deg C 350.96 0
59. ECO O/L TEMP, ACCOUSTIC Deg C -1.45 2.49
60. FG TEMP AT SRAPH-A I/L Deg C 379.13 348.67
61. FG TEMP AT SRAPH-B I/L Deg C 378.83 349.21
62. FG TMP AT I/L OF PAH-A Deg C 352.05 329.09
63. FG TMP AT I/L OF PAH-B Deg C 358.88 341.06
64. FG PRAPH A O/L TEMP Deg C 143.21 134.98
65. FG PRAPH B O/L TEMP Deg C 133.07 137.72
66. FG SRAPH A O/L TEMP Deg C 157.70 132.07
67. FG SRAPH B O/L TEMP Deg C 152.05 130.11
68. COMMON DUCT TEMP A Deg C 151.40 132.42
69. COMMON DUCT TEMP B Deg C 151.40 132.42
70. FG TMP AT ID A O/L Deg C 134.64 122.16
71. FG TMP AT ID B O/L Deg C 138.09 127.98
72. FG DP ACROSS SAHA mmWC 117.14 112.56
73. FG DP ACROSS SAHB mmWC 119.55 115.50
74. FG DP ACROSS PAHA mmWC 103.41 97.94
75. FG DP ACROSS PAHB mmWC 91.84 96.17
76. AIR DP ACROSS PAH-A mmWC 50.40 44.34
77. AIR DP ACROSS PAH-B mmWC 50.57 46.33
78. AIR DP ACROSS SAH-A mmWC 64.69 49.59

Before O/H After OH

20-05-08 25-06-08
79. AIR DP ACROSS SAH-B mmWC 53.32 49.77
80. PRAPH-A FG O/L DAMPER % 92.27 100.23
81. PRAPH-B FG O/L DAMPER % 69.98 94.74
82. SRAPH-A FG O/L DAMPER-1 % 79.44 75.12
83. SRAPH-A FG O/L DAMPER-2 % 76.24 81.26
84. SRAPH-B FG O/L DAMPER-1 % 92.79 81.69
85. SRAPH-B FG O/L DAMPER-2 % 97.58 77.20
86. BUR.TILT CORNER 1 CYLIN_POS Deg 63.88 64.40
90. IDF-A MTR CURRENT CH-1 Amp 276.12 299.74
91. IDF-A MTR CURRENT CH-2 Amp 314.86 284.84
92. IDF-B MTR CURRENT CH-1 Amp 307.03 313.50
93. IDF-B MTR CURRENT CH-2 Amp 183.91 218.91
94. FDF-A MTR CURRENT Amp 120.11 129.70
95. FDF-B MTR CURRENT Amp 122.77 136.45
96. PAF-A MTR CURRENT Amp 78.86 74.71
97. PAF-B MTR CURRENT Amp 78.57 73.17
98. MILL-A CURRENT Amp 0 121.00
99. MILL-B CURRENT Amp 119.29 116.72
100. MILL-C CURRENT Amp 92.33 109.66
101. MILL-D CURRENT Amp 106.03 113.28
102. MILL-E CURRENT Amp 106.36 118.79
103. MILL-F CURRENT Amp 106.03 113.28
104. MILL-G CURRENT Amp 118.71 124.13
105. MILL-H CURRENT Amp 0 0
106. MILL-J CURRENT Amp 115.44 118.57
107. MILL-K CURRENT Amp 95.67 0
108. MDBFP-C CURRENT Amp 0.21 0.19

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Area – TG

Before O/H After OH

20-05-08 25-06-08
36. COND HOTWELL TEMP Deg C 47.94 46.54
37. CONDENSER PR Kg/cm2 -0.89 -0.90
38. COND ABS. PR KG/CM2 0.11 0.10
39. CEP DISCH PR Kg/cm2 27.28 26.53
40. CEP DISCH TEMP Deg C 48.71 47.05
41. LPH 1 Cond I/L TEMP Deg C 50.81 49.01
42. LPH 1 DRN O/L TEMP Deg C 65.76 62.98
43. LPH 2 I/L COND TEMP Deg C 64.60 63.64
44. LPH 2 I/L EXT 2 STM TEMP Deg C 146.67 134.08
45. LPH 2 I/L EXT 2 STM PRESS Kg/cm2 0.96 0.91
47. LPH 3 I/L COND TEMP Deg C 107.33 105.49
48. LPH 3 O/L COND TEMP Deg C 129.79 128.51
49. LPH 3 I/L EXT 3 STM TEMP Deg C 215.25 206.26
50. LPH 3 I/L EXT 3 STM PRESS Kg/cm2 2.46 2.34
52. DEARATOR I/L COND TEMP Deg C 129.64 0
53. DEARATOR O/L COND TEMP Deg C 168.97 165.95
54. EXT STM PR TO D/A Kg/cm2 10.01 9.41
55. EXT STM TEMP TO D/A Deg C 308.80 301.87
56. DEAERATER PRESSURE Kg/cm2 7.78 7.31
57. BFP DISCH HDR PR Kg/cm2 208.61 204.45
58. BFP DISCH HDR TEMP Deg C 173.46 170.56
59. FW TEMP AT HPH 5A I/L Deg C 173.02 170.21
60. FW TEMP AT HPH 5A O/L Deg C 203.81 207.43
61. HPH 5A DRN O/L TEMP Deg C 181.45 178.12
62. HPH 5A EXT 5 STM I/L TEMP Deg C 420.73 419.33
63. EXT STM PRES AT HPH 5A I/L Kg/cm2 18.77 17.86
64. FW TEMP AT HPH 5B I/L Deg C 172.88 0
65. FW TEMP AT HPH 5B O/L Deg C 205.36 207.25
66. HPH 5B DRN O/L TEMP Deg C 183.63 0
67. EXT STM PRES AT HPH 5B I/L Kg/cm2 18.79 17.88
68. HPH 5B EXT 5 STM I/L TEMP Deg C 419.01 0
71. HPH 6A DRN O/L TEMP Deg C 210.44 0
72. HPH 6A DRN O/L to HPH 5A TEMP Deg C 204.31 202.27
73. CRH STM PRES AT HPH 6A I/L Kg/cm2 45.29 44.75

Before O/H After OH

20-05-08 25-06-08
74. CRH STM TEMP AT HPH 6A I/L Deg C 332.24 342.97
75. HPH 6A O/L FEED WTR PRESS Kg/cm2 202.84 200.84
78. HPH 6B DRN O/L TEMP Deg C 214.48 215.43
79. HPH 6B DRN O/L to HPH 5B TEMP Deg C 206.44 202.91
80. CRH STM PRES AT HPH 6B I/L Kg/cm2 45.23 44.77
81. CRH STM TEMP AT HPH 6B I/L Deg C 332.82 343.64
82. HPH 6B O/L FEED WTR PRESS Kg/cm2 202.53 201.03
83. FW PR AT ECO I/L Kg/cm2 198.57 197.31
84. FW TEMP AT ECO I/L Deg C 250.30 256.52
85. FW TEMP AT ECON O/L-LHS Deg C 319.05 325.44
86. FW TEMP AT ECON O/L-RHS Deg C 322.34 329.43
87. DRUM LEVEL mm -9.58 0.19
88. DRUM STM PRESSURE Kg/cm2 191.84 190.15
89. STM TMP-DESH I/L(LINE-A) Deg C 406.45 408.51
90. STM TMP-DESH I/L(LINE-A) Deg C 404.95 406.50
91. STM TMP-DESH I/L(LINE-B) Deg C 410.48 413.46
92. STM TMP-DESH I/L(LINE-B) Deg C 410.79 413.33
93. ST TMP P-SH HDR I/L LN-A Deg C 485.15 481.11
94. ST TMP P-SH HDR I/L LN-B Deg C 472.36 475.43
95. DESH OUTLET STEAM TEMP-L Deg C 399.13 395.96
96. DESH OUTLET STEAM TEMP-R Deg C 402.96 405.74
97. DESH O/L PR (LN-A) Kg/cm2 191.61 189.93
98. DESH O/L PR (LN-B) Kg/cm2 193.01 191.27
99. MS PR.AT BLR O/L(LINE-A) Kg/cm2 173.76 173.33
100. MS PR.AT BLR O/L(LINE-B) Kg/cm2 173.85 172.53
101. MS TMP SH O/L (LN-A) Deg C 543.58 541.11
102. MS TMP SH O/L (LN-B) Deg C 529.73 531.54
103. MS HDR TEMP Deg C 537.47 534.29
104. MS HDR TEMP Deg C 533.34 535.67
105. MS HDR PRESSURE Kg/cm2 170.34 168.93
106. THROTTLE PRESSURE Kg/cm2 170.34 168.93
107. MAIN STM PRESS.BEF ESV-1 Kg/cm2 165.57 165.40
108. MS TEMP BEF ESV-1 Deg C 528.45 526.41
109. MS TEMP BEF ESV-2 Deg C 529.63 528.03
110. HPT FIRST STAGE PR Kg/cm2 162.93 162.16
111. HPT EXHAUST PRESSURE Kg/cm2 46.61 45.33

Before O/H After OH

20-05-08 25-06-08
112. HPT EXHAUST TEMPERATURE Deg C 350.02 344.72
113. COLD REHEAT LINE TEMP Deg C 340.74 338.66
114. RH INLET TEMP BEFORE SPRAY-L Deg C 333.23 344.92
115. RH INLET TEMP BEFORE SPRAY-R Deg C 333.01 344.43
116. CRH PR RH I/L (L) Kg/cm2 46.20 45.78
117. CRH PR RH I/L (R) Kg/cm2 46.26 45.84
118. RH ST TMP-DESH O/L(LN-A) Deg C 297.88 284.10
119. RH ST TMP-DESH O/L-LN-B Deg C 277.20 262.59
120. RH ST TMP AT RH O/L-LN-A Deg C 525.90 538.83
121. RH ST TMP RH O/L (LN-B) Deg C 544.67 540.43
122. HRH PR.AT RE-HTR O/L(L) Kg/cm2 44.73 44.31
123. HRH PR.AT RE-HTR O/L(R) Kg/cm2 44.44 44.04
124. RH STM HDR TMP AT BLR O/L Deg C 544.06 541.60
125. RH ST HDR TMP BOILER O/L Deg C 545.33 541.87
126. HRH STM PRESS AT EXH CAS kg/cm2 46.61 45.33
127. HRH STM PRES BEF LPBP kg/cm2 43.74 42.44
128. STM PRESS BEF IPT BLDNG Kg/cm2 42.44 42.03
129. HRH STM TEMP BEF IV-1 Deg C 528.76 532.57
130. HRH STM TEMP BEF IV-2 Deg C 529.83 533.15
131. IPT EXHAUST TEMPERATURE Deg C 413.61 412.07
132. IPT EXHAUST PRESSURE kg/cm2 19.26 18.43
133. LPT EXHAUST TEMP. Deg C 47.42 46.40
134. LPT EXHAUST PRESSURE Kg/cm2 -0.89 -0.90
135. SH SP FW TMP AF FCV LN-A Deg C 172.54 170.28
136. SH SP FW TMP AF FCV LN-B Deg C 162.70 41.09
137. RH (LINE B) SPRAY TEMP Deg C 170.21 167.43
138. RH (LINE A) SPRAY TEMP Deg C 170.29 167.80
139. CEP A CURRENT Amp 160.69 152.78
140. CEP B CURRENT Amp 0.35 0
141. CEP C CURRENT Amp 158.43 150.82
142. TG ECWP A Amp 53.61 50.74
143. TG ECWP B Amp 0.01 51.43
144. TG ECWP C Amp 52.55 0.12
145. SG ECWP A Amp 0.38 149.83
146. SG ECWP B Amp 155.43 0.38
147. ACWP A Amp 187.09 0.19
148. ACWP B Amp 182.52 179.86
149. ACWP C Amp 0.19 177.19

Before O/H After OH

20-05-08 25-06-08
150. CWP A Amp 147.26 142.69
151. CWP B Amp 139.90 137.31
152. AXIAL SHIFT POSITION % -0.13 -0.12
155. HPT DIFF. EXPANSION MICRON -2.61 -3.51
156. IPT DIFF. EXPANSION MICRON 10.61 4.88
157. LPT DIFF. EXPANSION MICRON 16.77 21.86
158. GEN.EXCITATION FIELD VOLTAGE VOLTS 47.08 46.23
159. GEN.EXCITATION FIELD CURRENT AMPS 32.15 31.15
160. GEN STATOR R-PHASE AMPS 14209.53 13845.91
161. GEN STATOR Y-PHASE AMPS 14416.83 14075.50
162. GEN STATOR B-PHASE AMPS 14319.80 14020.60
163. GEN.STATOR CW IN TEMP. Deg C 44.99 44.98
164. GEN. COLD GAS TEMP.LEFT Deg C 40.33 40.10
165. GEN. COLD GAS TEMP.RIGHT Deg C 39.43 39.34
166. GEN. GAS PURITY % 99.90 99.92
167. DIFF.PR.ACROSS SEAL OIL/H2(TE) Kg/cm2 1.55 1.80
168. DIFF.PR.ACROSS SEAL OIL/H2(EE) Kg/cm2 1.59 1.88
169. GEN.EXCITATION H2 PRESSURE Kg/cm2 3.48 3.38
170. GEN. STATOR CW DP Kg/cm2 1.02 0.92
171. GEN.STATOR CW FLOW Kg/cm2 61.14 59.39
172. GEN.STATOR CW IN FLOW Kg/cm2 0.00 0.00
173. GEN STATOR SLOT TEMP. MAX Deg C 80.02 78.51
174. GEN STATOR SLOT TEMP. MIN Deg C 40.38 36.50
175. LUB. OIL TEMPERATURE Deg C 46.12 44.99
176. GEN.STATOR CW CONDUCTIVITY MS/sec 1.99 2.28
177. CEP DIS HDR PR KG/CM2 27.28 26.53
178. COND NRM MK UP INT READING T 235.76 306.34

TURBOVISSORY PARAMETERS
BEFORE & AFTER OVERHAUL.

TURBOVISORY PARAMETERS MONITORING SHEET

BEFORE & AFTER ANNUAL OVERHAUL, AT FULL LOAD OPEARTION.
Before OH At Rotor
Sl. Description of At 500 MW
UNIT at Full Load Zero At 360 RPM At 3000 RPM
No parameters.
Position
17/06/08 18/06/08 18/06/08 24/06/08
• DIFF EXPANSION 11:21hrs 13:30hrs 16:16hrs 13:55hrs
1. HPT (F) -5.0 &+3.5 mm -2.53 0.14 3.22 1.90 -3.54
2. IPT ® -1.0 &+5.5 mm 10.62 0.06 1.62 1.25 4.79
3. LPT® -3.0 &+35 mm 17.00 -0.09 7.90 4.18 22.2
• AXIAL SHIFT
4. Point (1) +/- 0.5 & +/- 1.0 mm -0.20 -0.11 -0.11 -0.08 -0.18
5. Point(2) mm -0.18 -0.12 -0.11 -0.09 -0.20
6. Point(3) mm -0.18 -0.12 -0.11 -0.09 -0.23
• OVERALL
EXPANSION
7. HPT (F) ( 0-30 MM) mm 0.15 5.72 8.16
8. IPT( R ) (0-20 MM) mm 0.04 2.59 2.88 12.95
• BBRNG VIBRATION >42 µ
9. HPT (F) 1X/1Y micron 15.03/17.76 3.7/3.3 11.3/16.7 19.1/14.6 24.9/24.9
10. HPT ®2X/2Y micron 21.4/15.6 2.9/2.9 18.7/10.1 18.7/18.1 20.1/16.2
11. IPT ® 3X/3Y micron 16.7/15.8 2.3/2.1 20.3/12.8 24.9/14.4 24.6/28.3
12. LPT® 4X/4Y micron 20.6/26.7 2.9/1.9 26.9/12.3 43.7/23.0 37.4/37.0
13. GEN(F) 5X/5Y micron 20.8/22.0 3.3/2.5 20.8/8.5 23.0/54.6 20.5/39.2
14. GEN® 6X/6Y micron 27.9/36.8 2.7/2.9 8.9/8.5 19.7/43.7 31.2/49.1
15. EXC® 7X/7Y micron 34.7/24.7 2.5/2.5 7.6/8.5 25.1/19.5 30.2/24.9
Shaft VIBRATION >100µ
16. HPT (F) 1X/1Y micron 100.9/139.3 20.5/4.8 39.0/30.4 75.9/58.6 83.7/51.3
17. HPT ®2X/2Y micron 97.8/88.4 3.3/3.9 87.2/70.8 111.0/56.2 129.0/97.6
18. IPT ® 3X/3Y micron 50.1/38.6 0.78/078 44.9/39.4 22.8/34.3 49.9/41.7
19. LPT® 4X/4Y micron 64.8/65.0 2.7/2.3 44.3/36.8 76.9/60.9 95.8/88.8
20. GEN(F) 5X/5Y micron 45.0/44.3 2.9/3.3 77.3/41.5 39.8/65.2 55.6/47.8
21. GEN® 6X/6Y micron 98.1/97.9 3.7/3.7 69.1/43.1 72.0/100.1 88.8/94.6
22. EXC® 7X/7Y micron 199.6/134.8 3.1/3.5 38.8/27.3 170.6/90.5 169.6/109.3
• Turbine Brng
110 / 130
Temp.
HPT (F)T Point 1,2 81/87
L/R
23.
B Point 3,4 73.2/68.2 64/58 75.1/71.2 52/76
L/R
HPT (R) T Point 5,6 62.4/75.1 60/73 58.5/76.1 64/65

L/R
24.
B
L/R Point 7,8 63.4/65.3 61/58 62.4/65.3 52/68

Before OH At Rotor
Sl. Description of At 500 MW
UNIT at Full Load Zero At 360 RPM At 3000 RPM
No parameters.
Position
T Bearing Point 9,10 57.7/78.0 55/73 54.6/72.2 62/64
25. FL/FR
RL/RR Point 11,12 67.3/69.3 63/62 69.3/65.3 64/56
26. IPT (R) Point 13,14 63.4/62.4 60/59 61.4/59.5 88/84
27. LPT (R) Point 15,16 86.8/90.7 84/85 82.9/86.8 85/88
Point 17,18 85.8/89.7 89/89 90.7/89.7 78/77
28. GEN (TE)
Point 19,20 81.0/81.0 73/72 72.2/72.2 72/72
Point 21,22 74.1/74.1 67/67 67.3/67.3 81/81
29. GEN (EE)
Point 23,24 80.0/80.0 77/77 78.0/79.0 78/78
Exciter Point 25,26 80.0/80.0 77/77 77.1/77.1 64/64
30.
Brng. Point 27,28 65.3/65.3 61/62 63.4/71.2 62/62
BRNG Drain Oil TEMP 65.3/65.3 48.8/48.8 62/62 62.4/63.4
1. Return Oil Temp HPF 0 C
2. Return Oil Temp HPR 0 C 60.51 49.7 57.8
3. Return Oil Temp IPR 0 C 56.36 51.9 53.1
4. Return Oil Temp LPR 0 C 71.00 65.1 66.8
5. Return Oil Temp Gen F 0 C 71.00 68.5 70.5
6. Return Oil Temp Gen R 0 C 64.90 61.2 61.7
7. Return Oil Temp Exciter 0 C 65.15 61.9 62.9
8. MOT Level MM 56.36 52.2 53.1
9. Lub Oil Hdr Pres Ksc 923 915
Lub Oil Hdr Temp Bef
10. 0 C 64.42
Cooler
Lub Oil Hdr Temp Aft
11. 0 C 45.63
Cooler

Boiler Safety Valve Floating Parameters

MS MDBF
Drum MS MS Hdr HRH HRH Hdr RH Metal MDBFP Feed at Drum Total BLI as
Date Time Throttl BP 1 BP 2 LPBP 1 LPBP 2 P Suc BLI
Pr Pree Temp Press Temp temp Max speed ECO lvl Feed %
e Pr flow
6/18/2008 5:18:00 AM 66.2 65.08 64.53 391.77 50.23 50.47 10.03 343.35 366.11 17.06 23.77 3,530.40 226.95 -30.13 591.36 226.48 316.54 17.59
6/18/2008 5:12:00 AM 66.14 65.08 64.53 392.56 49.76 49.99 10.04 334.57 356.44 17.03 23.76 3,534.00 227.63 33.94 586.19 227.81 311.41 17.3
6/18/2008 5:06:00 AM 66.08 65.08 64.53 394 49.35 49.46 10.06 326.65 346.08 16.41 23.03 3,537.00 227.8 80.5 586.63 227.81 308.18 17.12
6/18/2008 5:00:00 AM 66.06 65.1 64.57 395.62 48.5 48.45 10.08 322.26 337.59 15.49 21.97 3,532.80 230.52 104.5 593.23 229.9 300.96 16.72
6/18/2008 4:54:00 AM 66 65.04 64.49 397.57 48.95 48.84 10.08 326.25 338.83 22.1 29.02 3,528.60 238.51 46.69 605.22 239.02 304 16.89
6/18/2008 4:48:00 AM 65.92 65 64.49 399.69 48.49 48.51 10.08 340 347.94 23.43 30.77 3,515.40 216.92 143.81 639.32 216.6 296.02 16.44
6/18/2008 4:42:00 AM 66.02 65.14 64.66 401.96 47.82 47.7 10.02 348.82 351.35 22.19 29.09 3,587.40 238.51 138.69 670.01 238.64 295.07 16.37
6/18/2008 4:36:00 AM 66.82 65.18 65.05 404.98 58.95 59.1 10.05 357.79 359.72 37.74 44.12 3,833.40 404.94 -115.81 827.09 404.32 373.73 20.77
6/18/2008 4:30:00 AM 76.2 74.48 74.9 409.3 55.75 56.14 10.12 393.36 384.9 40.77 47.03 3,503.40 264.69 62.06 683.98 265.43 410.59 22.8
6/18/2008 4:24:00 AM 84.1 82.88 83.25 413.08 50.6 50.47 10.04 417.69 403.19 38.51 44.61 3,835.80 359.21 78 791.67 359.48 361.38 20.09
6/18/2008 4:18:00 AM 94.42 93.04 94.01 418.81 51.01 50.93 10.11 427.41 419.24 43.41 49.21 3,930.60 349.69 -59.94 796.62 350.74 413.63 22.98
6/18/2008 4:12:00 AM 107.4 106.4 107.48 425.58 47.5 47.68 10.04 431.62 428.54 34.07 40.65 4,060.20 342.38 41.94 753.06 342.76 389.88 21.69
6/18/2008 4:06:00 AM 121.36 120.58 121 425.76 43.39 43.35 8.97 432.2 432.2 34.27 41.12 4,172.40 310.08 80.13 720.39 310.27 375.25 20.82
6/18/2008 4:00:00 AM 129.54 128.96 129.55 420.28 41.54 41.53 7.87 431.62 434.06 37.2 43.84 4,441.80 424.66 -77.25 841.61 425.22 362.9 20.12
6/18/2008 3:54:00 AM 140.72 140.24 139.93 410.42 39.86 40.13 6.01 431.88 435.55 48.33 54.38 4,687.80 330.48 87.75 780.78 329.65 335.16 18.69
1,056.5
6/18/2008 3:48:00 AM 149.02 148 150.35 410.53 46.95 47.37 7.36 434.9 447.39 81.93 87.99 5,044.80 614.38 -151.38 615.03 491.34 27.25
5
6/18/2008 3:42:00 AM 180.28 179.34 180 425.07 31.97 34.86 7.12 431.19 442.68 42.54 49.93 5,074.80 355.13 -16.69 845.57 357.01 442.32 24.64
6/18/2008 3:36:00 AM 177.24 176.88 175.14 421.54 34.41 28.88 5.19 428.78 441.69 41.76 48.49 4,977.00 358.87 -59.75 839.63 357.77 290.89 16.14
6/18/2008 3:30:00 AM 175.04 174.5 173.77 420.43 37.53 37.77 5.19 426.51 439.27 55.98 61.77 4,963.20 396.27 -140.63 875.38 396.72 359.67 20
6/18/2008 3:24:00 AM 175.9 175.46 174.35 416.47 27.21 27.05 5.27 422.37 426.31 48.19 55.2 4,809.00 292.23 -103.63 768.02 292.6 320.15 17.77
6/18/2008 3:18:00 AM 175.04 174.94 173.99 414.2 16.53 16.51 5.21 420.93 424.27 28.59 36.23 4,754.40 259.08 -99.63 732.16 259.16 249.85 13.88
6/18/2008 3:12:00 AM 175.02 174.94 173.97 411.72 15.98 16.05 5.22 420.28 420.67 27.58 35.35 4,717.20 227.12 -50.38 699.6 226.48 246.24 13.67
6/18/2008 3:06:00 AM 175 174.98 174.02 408.62 13.6 13.37 5.18 419.96 418.93 19.21 26.43 4,756.20 234.94 99.88 706.86 233.89 225.91 12.55
6/18/2008 3:00:00 AM 174.42 174.34 173.43 407.5 25.9 25.96 5.17 420.82 419.62 30.16 37.46 4,871.40 311.78 23.19 789.58 311.41 250.23 13.89
6/18/2008 2:54:00 AM 175.04 174.88 173.93 407.9 30.78 30.67 5.19 421.08 421.04 34.56 41.49 4,866.00 306.68 -23.19 782.32 306.28 270.56 15.03
6/18/2008 2:48:00 AM 175.08 174.9 173.95 408.87 31.59 31.45 5.19 421.4 422.9 35.98 42.69 4,878.00 312.46 -53.94 789.91 311.79 276.45 15.37

MS MDBF
e Pr flow
6/18/2008 2:42:00 AM 175.12 174.92 173.97 410.71 32.14 32.13 5.2 421.18 422.1 37.09 43.69 4,879.80 314.5 -77.5 792.11 314.83 281.77 15.65
6/18/2008 2:36:00 AM 175.16 174.94 173.99 412.65 32.26 32.41 5.19 420.46 425.13 37.24 43.83 4,876.20 314.84 -91.31 793.54 314.64 284.24 15.8
6/18/2008 2:30:00 AM 174.98 174.78 173.95 413.84 31.54 31.46 5.2 419.02 422.72 36.68 43.22 4,816.80 284.75 -82.31 764.17 285 285.19 15.84
6/18/2008 2:24:00 AM 174.32 174.18 172.98 412.87 21.74 21.86 5.2 417.08 420.79 29.47 37.17 4,768.80 253.47 14.69 729.3 252.89 254.79 14.16
6/18/2008 2:18:00 AM 171.94 171.82 170.73 411.61 20.7 20.87 5.2 415.64 418 28.52 36.33 4,752.00 257.89 60.19 731.61 258.02 250.99 13.95
6/18/2008 2:12:00 AM 171.16 171.08 170.05 411 16.58 16.63 5.21 414.52 415.09 25.82 33.64 4,749.00 291.04 -6.81 759.99 291.27 242.82 13.49
6/18/2008 2:06:00 AM 168.74 168.58 167.44 410.17 18.92 18.71 5.21 413.7 413.79 27.59 35.52 4,681.80 239.36 -39.19 711.92 239.97 249.66 13.85
6/18/2008 2:00:00 AM 165.38 165.18 163.84 408.62 16.49 16.61 5.22 413.08 410.81 26.06 33.91 4,686.60 238.68 75.19 709.83 238.64 239.78 13.32
6/18/2008 1:54:00 AM 161.48 161.28 160.16 407.68 26.41 26.49 5.19 412.94 411.37 28.07 35.76 4,720.20 268.09 32.44 736.56 267.71 248.9 13.83
6/18/2008 1:48:00 AM 160.54 160.32 159.43 407.36 30.84 30.69 5.2 412.62 410.94 30.33 37.98 4,725.60 262.14 47 734.91 262.2 260.11 14.46
6/18/2008 1:42:00 AM 160.52 160.32 159.44 407.04 30.43 30.5 5.19 412.04 410.32 29.68 37.42 4,731.60 265.03 61.19 735.57 265.43 257.64 14.32
6/18/2008 1:36:00 AM 160.5 160.3 159.39 406.78 30.22 30.1 5.2 411.5 410.13 29.34 37.05 4,723.20 261.46 68.88 732.71 261.44 255.55 14.21
6/18/2008 1:30:00 AM 160.58 160.4 159.52 406.24 27.86 27.78 5.2 410.85 408.39 27.35 35.17 4,716.60 268.6 66.94 731.83 268.28 250.8 13.93
6/18/2008 1:24:00 AM 160.36 160.16 159.37 405.52 30.32 30.2 5.2 410.1 408.08 30.16 37.65 4,696.20 288.83 -67.75 752.95 288.61 258.02 14.33
6/18/2008 1:18:00 AM 160.9 160.72 159.75 403.9 22.02 21.85 5.19 409.09 405.23 26.14 34.14 4,579.20 226.44 -12.13 687.17 225.91 247 13.73
6/18/2008 1:12:00 AM 159.96 159.82 158.76 402.32 17.67 17.55 5.16 408.62 406.53 20.18 27.56 4,577.40 232.05 38.38 686.73 231.42 233.89 12.99
6/18/2008 1:06:00 AM 160.08 159.86 159.01 403.76 31.44 31.7 4.88 408.84 407.71 34.64 41.66 4,772.40 336.09 -78.88 799.92 335.92 263.53 14.65
6/18/2008 1:00:00 AM 160.4 160.14 159.25 406.32 32.97 33 4.21 407.65 407.77 41.73 47.86 4,702.80 293.42 -74.69 759.55 294.12 276.64 15.37
6/18/2008 12:54:00 AM 160.6 160.28 159.48 408.84 31.81 32.13 4.21 405.34 406.6 41.78 48.12 4,656.00 273.02 -46.75 734.8 272.84 280.82 15.62
6/18/2008 12:48:00 AM 159.5 159.24 157.91 409.59 23.2 23.62 3.74 401.96 403.56 31.79 38.99 4,606.20 239.7 27.69 700.59 239.59 244.15 13.56
6/18/2008 12:42:00 AM 154.74 154.46 152.91 409.05 18.66 19.02 3.72 399.33 401.45 32.63 39.89 4,553.40 243.27 41.75 698.06 242.44 233.7 12.98
6/18/2008 12:36:00 AM 149 148.66 147.28 407.86 23.12 23.15 3.51 396.96 399.59 31.35 38.7 4,475.40 227.97 12.06 674.52 227.05 236.74 13.15
6/18/2008 12:30:00 AM 143.14 142.8 141.34 405.7 19.27 19.14 2.62 393.82 394.82 39.64 45.9 4,401.00 214.2 82.06 656.26 213.37 230.85 12.83
6/18/2008 12:24:00 AM 136.32 135.92 134.46 402.97 23.28 23.47 2.56 391.27 392.65 38.99 45.29 4,244.40 215.39 55.69 646.03 215.27 228.57 12.7
6/18/2008 12:18:00 AM 128.84 128.44 126.99 400.05 19.07 19.25 2.6 388.42 389.42 35.15 41.97 4,148.40 195.84 81.06 620.07 194.94 220.02 12.22
6/18/2008 12:12:00 AM 121.88 121.48 119.99 398.04 20.11 20.1 2.56 386.55 387.13 32.31 39.46 4,132.80 212.67 127.06 631.18 212.04 239.59 13.31
6/18/2008 12:06:00 AM 116.84 116.42 115.16 397.14 32.08 32.13 2.52 385.69 388.12 39.8 46.29 4,095.00 262.99 45.75 674.96 262.96 254.6 14.17
6/18/2008 12:00:00 AM 115.58 115.06 114.28 396.6 35.22 35.16 2.62 382.59 385.52 49.05 55.06 4,133.40 237.32 23.31 652.63 238.26 285.57 15.85
6/17/2008 11:54:00 PM 113.5 113.04 112.09 395.59 32.46 32.51 2.55 379.75 385.27 44.71 50.88 4,099.80 265.2 13.56 671.44 264.67 261.82 14.56

MS MDBF
e Pr flow
6/17/2008 11:48:00 PM 112.5 111.9 110.93 393.86 32.67 32.82 2.66 374.96 379.13 49.24 55.57 3,870.60 228.48 1.38 620.84 228.76 287.66 15.98
6/17/2008 11:42:00 PM 109.06 108.56 107.23 391.34 29.22 29.54 2.52 370.78 375.97 35.16 42.25 3,742.20 187.85 59.06 576.29 188.67 248.14 13.78
11:36:00
6/17/2008 104.92 104.44 103.43 389.86 32.39 32.43 2.61 367.62 374.23 35.94 42.72 3,891.60 251.26 43.56 642.84 251.37 245.86 13.65
PM
11:30:00
6/17/2008 102.78 102.16 101.41 388.46 36.64 36.67 2.6 363.94 369.64 44.94 51.1 3,780.60 209.27 14.38 591.47 209.38 277.97 15.43
PM
11:24:00
6/17/2008 100.78 100.28 99.09 385.83 26.05 26.31 2.58 357.97 363.82 25.78 33.55 3,827.40 194.14 -10.06 584.65 194.56 227.05 12.63
PM
11:18:00
6/17/2008 95.2 94.72 93.6 383.35 31.92 32.31 2.53 355.27 362.2 28.11 35.57 3,830.40 156.91 81.25 547.36 156.75 232.37 12.9
PM
11:12:00
6/17/2008 89.9 89.44 88.27 381.87 32.91 36.22 2.55 353.54 362.33 32.23 39.17 3,796.20 207.74 58.44 591.47 207.48 235.98 13.1
PM
11:06:00
6/17/2008 87.08 86.5 85.66 380.72 38.74 38.98 2.59 350.23 364.13 42.75 48.85 3,888.00 249.9 55.56 634.37 247.38 267.14 14.85
PM
11:00:00
6/17/2008 86.24 85.42 84.98 380.11 42.09 42.4 2.56 345.3 366.23 56.77 62.57 3,897.60 254.15 -19.44 645.26 254.22 303.62 16.87
PM
10:54:00
6/17/2008 87.22 86.36 85.77 378.27 41.21 41.35 2.58 336.69 361.71 51.47 57.31 3,870.60 252.11 -0.75 642.4 252.32 295.83 16.45
PM
10:48:00
6/17/2008 87.36 86.52 85.79 374.96 39.46 39.68 2.61 325.42 356.44 44.53 50.96 3,847.20 258.74 -6.94 641.3 258.78 284.81 15.82
PM
10:42:00
6/17/2008 84.82 84.04 83.21 371.4 37.58 37.83 2.61 314.59 351.48 37.51 44.23 3,642.60 194.31 -54.63 563.75 193.42 269.8 14.97
PM
10:36:00
6/17/2008 81.14 80.28 79.47 368.66 39.67 39.85 2.57 306.2 352.41 43.96 50.11 3,729.00 255.34 -127 634.15 255.93 267.52 14.9
PM
10:30:00
6/17/2008 80.7 79.82 79.24 364.05 39.56 39.79 2.6 289.86 341.5 38.83 45.37 3,810.00 162.01 8.88 564.74 162.26 276.64 15.37
PM
10:24:00
6/17/2008 77.76 77.16 76 358.08 32.92 33.32 2.73 274.63 334.12 19.71 27.37 3,798.00 196.18 -50.81 588.61 197.98 218.12 12.12
PM
10:18:00
6/17/2008 71.92 71.2 69.97 351.42 36.16 36.27 3.13 264.8 328.6 18.03 25.6 3,640.80 162.35 -61.13 533.83 162.83 227.81 12.64
PM
10:12:00
6/17/2008 66.44 65.74 64.33 343.03 36.18 36.3 2.71 252.02 318.25 19.03 26.65 3,621.60 148.07 -47.69 525.03 148.01 220.97 12.29
PM
10:06:00
6/17/2008 60.76 60.08 58.81 332.98 36.16 36.32 2.11 239.42 307.4 20.42 28.12 3,505.80 96.56 85.56 469.37 96.33 213.18 11.84
PM
10:00:00
6/17/2008 54.28 53.62 52.18 322.08 36.16 36.36 1.51 227 294.38 24.74 32.77 3,480.60 151.3 -0.94 515.9 149.91 204.63 11.35
PM
6/17/2008 9:54:00 PM 47.68 47.08 46.06 311.85 36.16 36.4 1.19 215.66 283.03 24.55 32.49 3,412.20 114.41 -2.88 481.58 114.38 195.13 10.85
6/17/2008 9:48:00 PM 41.5 40.9 39.83 303.1 36.15 36.45 0.91 205.54 273.61 23.65 31.7 3,436.20 75.48 19.63 444.84 75.43 186.58 10.37
6/17/2008 9:42:00 PM 36.96 36.5 35.73 296.48 36.16 36.5 0.72 200 266.04 23.47 31.5 3,430.80 81.09 -5.75 442.2 81.89 180.69 10.02
6/17/2008 9:36:00 PM 35.56 35.12 34.49 290.36 36.16 36.5 0.7 200 259.28 22.85 30.85 3,423.00 83.3 33.13 450.01 83.79 179.74 9.96
6/17/2008 9:30:00 PM 34.26 33.82 33.16 283.92 36.15 36.51 0.61 200 249.49 23.2 30.99 3,344.40 106.76 -53.25 465.85 106.02 177.46 9.84
6/17/2008 9:24:00 PM 32.6 32.18 31.37 278.55 32.48 31.86 0.16 200 239.01 23.32 31.07 3,271.80 43.35 10.25 393.58 43.7 168.34 9.33

MS MDBF
e Pr flow
6/17/2008 9:18:00 PM 29.66 29.34 28.73 275.67 30.65 29.91 0 200 234.36 22.39 30.06 3,256.80 40.97 70.75 399.52 41.23 159.41 8.83
6/17/2008 9:12:00 PM 28.84 28.54 28.03 273.73 30.65 29.98 0 200 231.88 22.69 30.21 3,253.20 42.67 115.63 395.34 42.18 158.84 8.82
6/17/2008 9:06:00 PM 28.32 28.02 27.54 271.53 30.65 30.04 0 200 230.27 22.11 29.68 3,226.80 75.48 131.19 427.13 74.29 157.89 8.78
6/17/2008 9:00:00 PM 27.7 27.36 26.8 269.16 30.65 30.07 0 200 226.49 22.31 29.94 3,220.20 80.24 38.25 431.42 79.42 157.32 8.8
6/17/2008 8:54:00 PM 27.34 26.94 26.46 266.6 30.65 30.12 0 200 224.07 22.04 29.57 3,243.00 43.86 121.69 396.11 43.51 156.75 8.72
6/17/2008 8:48:00 PM 26.98 26.58 26.06 263.86 30.65 30.12 0 200 219.73 22.47 29.97 3,232.80 138.72 -23.06 477.4 137.94 157.13 8.71
6/17/2008 8:42:00 PM 26.72 26.24 25.85 260.55 23.17 25.95 0.32 200 214.95 16.09 22.5 3,189.00 58.82 -18.94 407.55 59.47 154.66 8.6
6/17/2008 8:36:00 PM 26.52 26.02 25.49 256.81 21.67 25.17 2.03 200 205.72 1.12 3.64 3,183.00 58.14 34.19 407 57.95 153.9 8.52
6/17/2008 8:30:00 PM 26.3 25.8 25.34 252.6 21.67 25.23 1.49 200 197.66 0.01 1.39 3,207.00 58.99 28.13 412.61 59.09 153.9 8.5
6/17/2008 8:24:00 PM 26.06 25.52 25.02 247.92 21.68 25.32 0.63 200 185.38 0 1.34 3,211.80 59.16 -9.19 413.27 56.81 151.81 8.49
6/17/2008 8:18:00 PM 25.94 25.4 24.93 238.48 20.55 24.15 0.06 200 164.61 0.01 1.33 3,199.80 57.29 43.94 403.04 56.43 150.48 8.39
6/17/2008 8:12:00 PM 25.64 25.22 24.68 229.38 9.77 9.31 0 200 142.29 0.01 1.34 3,213.60 73.95 18.81 425.59 74.86 135.66 7.57
6/17/2008 8:06:00 PM 25 24.6 24.07 227.61 7.9 8.36 0 200 133.24 0.01 1.34 3,203.40 63.24 -0.31 407.88 63.27 133.95 7.39
6/17/2008 8:00:00 PM 24.32 23.92 23.38 226.03 6.18 5.91 0 200 129.83 0.01 1.36 3,213.00 39.27 24.31 395.89 39.71 132.81 7.4
6/17/2008 7:54:00 PM 23.54 23.08 22.23 220.41 0.87 1.36 0 200 126.73 0.02 1.36 3,246.00 93.84 -26.81 453.42 94.43 125.97 7.11
6/17/2008 7:48:00 PM 22.92 17.14 16.51 207.34 0.2 0 0 200 124.87 0.01 1.36 3,257.40 48.28 -17.69 415.47 47.88 125.59 6.98
6/17/2008 7:42:00 PM 22.24 14.28 13.46 200 0.12 0 0 200 123.19 0.01 1.4 3,252.60 47.26 6.38 405.13 48.45 127.3 7.07
6/17/2008 7:36:00 PM 21.62 8.26 7.13 200 0.16 0 0 200 121.09 0.01 1.44 3,261.00 48.28 21.56 411.95 49.02 137.75 7.65
6/17/2008 7:30:00 PM 21.02 3 2.21 200 0.43 0 0 200 119.35 0 1.49 3,127.80 45.05 25.19 395.12 45.03 159.98 8.89
6/17/2008 7:24:00 PM 20.36 0.78 0.23 200 0.88 0 0 200 116.5 0.01 1.52 3,006.60 33.15 63.63 365.64 33.44 123.31 6.86
6/17/2008 7:18:00 PM 19.48 0.24 0 200 0.95 0 0 200 115.01 0.01 1.54 3,021.60 31.79 60.38 382.47 31.73 36.1 2
6/17/2008 7:12:00 PM 18.2 0.2 0 200 0.96 0 0 200 110.61 0.58 2.5 3,028.20 29.92 61 378.07 34.01 26.98 1.5
6/17/2008 7:06:00 PM 16.96 0.18 0 200 0.92 0 0 200 108.25 0 1.25 3,015.00 33.32 68.5 358.49 33.44 19 1.06
6/17/2008 7:00:00 PM 15.76 0.2 0 200 1.34 0.17 0 200 107.57 0.01 1.24 2,984.40 39.61 79.38 372.79 38 23.56 1.3
6/17/2008 6:54:00 PM 14.6 0.2 0 200 1.77 0.44 0 200 107.82 0.01 1.2 2,989.80 41.99 71.06 375.32 43.51 24.7 1.38
6/17/2008 6:48:00 PM 13.44 0.2 0 200 1.78 0.44 0 200 108.31 0.01 1.27 3,105.00 28.05 59 365.42 29.64 25.84 1.44
6/17/2008 6:42:00 PM 12.24 0.18 0 200 1.76 0.44 0 200 111.54 0 1.33 3,334.20 35.19 36.44 401.39 34.39 14.82 0.84
6/17/2008 6:36:00 PM 10.96 0.18 0 200 1.8 0.44 0 200 115.69 0.01 1.34 3,340.80 32.64 -11.06 404.69 33.25 25.08 1.39
6/17/2008 6:30:00 PM 9.74 0.2 0 200 1.77 0.44 0 200 120.96 0.01 1.35 3,339.00 32.3 24.38 393.25 32.87 35.15 1.96

MS MDBF
e Pr flow
6/17/2008 6:24:00 PM 8.24 0.22 0 200 1.78 0.44 0 200 125.74 0.01 1.35 3,337.80 70.21 162.69 419.1 70.68 38.57 2.14
6/17/2008 6:18:00 PM 6.4 0.22 0 200 1.76 0.44 0 200 123.38 0.01 1.34 3,579.60 45.56 81.75 427.9 40.28 39.14 2.17
6/17/2008 6:12:00 PM 4.8 0.22 0 200 1.76 0.44 0 200 121.64 0.01 1.34 3,590.40 32.64 106.81 434.5 32.49 39.14 2.17
6/17/2008 6:06:00 PM 3.86 0.22 0 200 1.77 0.44 0 200 120.03 0.01 1.35 3,616.80 32.64 108.81 418.33 30.4 39.14 2.18
6/17/2008 6:00:00 PM 3.08 0.22 0 200 1.77 0.44 0 200 116.13 0.01 1.35 3,582.00 31.79 89.13 425.92 26.41 39.33 2.18
6/17/2008 5:54:00 PM 2.42 0.22 0 200 1.78 0.44 0 200 113.21 0.01 1.34 3,490.20 27.88 103.63 411.84 29.26 39.71 2.21
6/17/2008 5:48:00 PM 1.9 0.22 0 200 1.76 0.44 0 200 105.03 0 1.33 3,510.60 20.91 145.88 411.95 19.38 40.28 2.23
6/17/2008 5:42:00 PM 1.66 0.22 0 200 1.77 0.44 0 200 98.77 0 1.32 3,398.40 4.93 158.06 384.56 7.03 40.47 2.25
6/17/2008 5:36:00 PM 1.44 0.22 0 200 1.77 0.44 0 200 96.91 0.01 1.32 3,141.00 9.86 188.5 354.31 10.45 40.47 2.24
6/17/2008 5:30:00 PM 1.24 0.22 0 200 1.78 0.44 0 200 96.6 0.01 1.31 3,142.80 1.36 250 342.76 0.57 40.28 2.24

CW Pump Discharge Valve Operation Check
Description 6A 6B
Local Remote Local Remote
Full close to
Crack open in 04:07 03:00
04:30 04:00
Sec
Crack Open to full
31:00 30:20 33:43 33:60
open in Sec
Full open to full
close (Normal) in 41:16 40:07 48:30 49:00
Sec
Emergency close
35:46
in Sec
Main Turbine gland steam Pr. Controller manual checking parameter
Leak off v/v Supply v/v

-94.12 97.21
-73.53 73.79
-55.64 54.22
-25.17 20.11
-0.57 0.59
25.61 21
54.71 52.62
70.66 69.78
99.8 1000

Generator air Leak test Parameters
Cold gas Cold gas Hot gas Temp A

Time Air pressure C&D
Temp.(Left) Temp.(Right) &B
14/06/08 KSC 0C 0C
02:30 4.00 35 .0 35.0

03:30 3.98 35.14 34.65
04:30 3.96 35.14 34.40
05:30 3.94 34.89 34.16
13:00 3.94 34.6 34.1
15:30 3.91 34.4 33.6
16:00 3.90 34.4 33.6
17:00 3.89 34.4 33.90
18:00 3.88 34.4 33
18:50 3.87 34 33.67
19:25 3.87 34.40 33.67
20:00 3.86 34.40 33.67
15/6/08
10:00 3.72 32 32
18:00 3.93 33.92 33.13
19:00 3.92 33.43 32.70
19:30 3.91 33.43 32.70
20:00 3.90 33.43 32.70
21:00 3.88 33.43 32.70
16/6/08
09:00 3.72 32.45 31.96
10:45 3.71 32.45 31.96
11:40 3.70 32.45 31.96
12:37 3.69 32.45 31.96
13:40 3,68 32.45 31.96
16:30 3.65 32.45 31.96
21:00 3.59 31.48 31.72

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TALCHER SUPER THERMAL POWER PROJECT

TSTPP , STAGE – II UNITS

Compiled By Recommissioning Group Page 3

Compiled By Recommissioning Group Page 4

Area Boiler & ash handling

Complete replacement of coal & oil burners

Compiled By Recommissioning Group Page 5

Area TG & auxiliaries

Condenser HP Bullet Cleaning

Compiled By Recommissioning Group Page 6

Compiled By Recommissioning Group Page 7

Compiled By Recommissioning Group Page 8

Sl. No. Name Group Designation

Compiled By Recommissioning Group Page 9

HISTORY OF THE UNIT

Compiled By Recommissioning Group Page 10

TALCHER SUPER THERMAL POWER STATION

Description. Unit # 3 Unit # 4 Unit # 5 Unit # 6

No of months from “0” date 38 months 1 day

Synch to coal firing( in no of days ) 45 25 32 52

Full load achieved 26.03.03 14.01.04 21.08.04 08.07.05

BLU to full load

Synch to full load 81 81 100 152

TRIAL OPEARTION OF THE UNITS

Description Unit # 3 Unit # 4 Unit # 5 Unit # 6

Compiled By Recommissioning Group Page 11

Various Protocols &

Compiled By Recommissioning Group Page 12

VARIOUS PROTOCOLS USED

Compiled By Recommissioning Group Page 13

Details of Recommissioning check Lists Followed

Compiled By Recommissioning Group Page 14

Compiled By Recommissioning Group Page 15

UNIT- 6 RECOMMISSIONING HIGHLIGHTS

Sl Description of the No of days

Compiled By Recommissioning Group Page 16

UNIT- 6 RECOMMISSIONING ACTIVITIES.

• U-5 Overhaul (June ’06) = 28:34 Hrs

Compiled By Recommissioning Group Page 17

Compiled By Recommissioning Group Page 18

MODIFICATIONS /IMPROVEMENTS CARRIED OUT

Area : Boiler & Auxiliaries

Compiled By Recommissioning Group Page 19

Area : Turbine & Auxiliaries

Compiled By Recommissioning Group Page 20

Compiled By Recommissioning Group Page 21

MAJOR PROBLEMS DURING

Compiled By Recommissioning Group Page 22

MAJOR PROBLEMS EXPERIENCED

AREA : BOILER & AUXILIARIES

Compiled By Recommissioning Group Page 23

Surprises & Learning’s on

Compiled By Recommissioning Group Page 24

Surprises & Learning’s on

SL.NO. AREA OBSERVATION

Compiled By Recommissioning Group Page 25

NEW METHODS / PROCEDURES

Compiled By Recommissioning Group Page 26

NEW METHODS / PROCEDURES ADOPTED

BOILER & AUXILIARIES

Compiled By Recommissioning Group Page 27

Suggestions For Further

Compiled By Recommissioning Group Page 28