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O&M PROBLEMS OF THERMAL TIFR recruitment 2020 | ₹70,000/- PM
March 27, 2019 admin 28 Comments CBI recruitment 2020 | Final Year
Eligible | No Exam , No fee (FREE) |
COMMONLY FACED O&M PROBLEMS OF THERMAL POWER STATIONS How to apply ?
Mech. Systems
EXPLORE JOBS
1.2.1. Pressure Parts, Furnace & Second PASS
BE/BTECH
DIPLOMA
1.2.3. Isolating valves ( motorised & manual)
PRIVATE JOBS
APPRENTICE
1.2.5. Control valves
ITI
1.2.6. Soot blowers systems
Electrical System :
4.0. Gas Turbine (GE make)
Frequent tube failures :
1. Check for interruption of coal to the furnace due to choking in the burner
2. Check for tripping of feeder/mill
3. Check for disturbed combustion inside furnace
4. Check for any boiler tube leakage
5. Check for opening of boiler drains, vent, safety valves
6. Check for choking in mills/drop in air flow through mill
7. Check for malfunctioning of auto control of CMC/Fuel master control
1. Check for any boiler tube leakage
2. Check for leakages from glands and bonnets of valves
3. Check for passing of safety valves
4. Check for passing of drain valves
5. Check for passing of vent valves
6. Check for optimum opening of CBD valves
1.1.14. Ash build up in bottom ash hopper and water walls:
Mechanical System :
Pressure Parts :
1. Check for deposits inside the tube. Analyze the deposits.
2. Check for indications for overheating of the failed tube and the nearby tubes.
3. Check the tube thickness of the failed tube and also nearby tubes.
4. Check the healthiness of nearby wall blowers for steam passing
5. Check for possibility of choking/loss of adequate flow through the tube
6. In case of scales/chemicals deposits/Rust contact BHEL for further analysis
and chemical cleaning
7. Check for foreign materials/obstructions in water wall ring headers
8. Check for possibility of failure of weld joint
9. Check the orifices of the tubes in the ring header in case of controlled
circulation boilers.
Superheater/Reheater/Economiser/Tube failure:
1. Check for indications for overheating of the failed tubes and the nearby tubes
2. Check for failure of weld joint
3. Check the tube thickness of the failed tube and the nearby tubes
4. Check the healthiness of nearby long retractable soot blower for steam
passing
5. Check for possibility of choking/loss of adequate flow through the tubes
6. Check for foreign materials/obstructions in the connected headers
7. Check the tube material for usage of proper grade material
8. In case of scales/chemicals deposits/rust contact BHEL for further analysis
and remedial measures
9. Check the spacing and alignment of coils around the failed tube
10. Check the availability/healthiness of tube shields/cassette baffles
Unloading/overloading of hangers :
1. Verify the correctness of the hanger as per hanger schedule
2. Reset all the hangers of the connected header, pipe, pressure part to the cold
set values.
3. Measure the hot value of the hanger and report to Engineering for analysis.
Fast erosion of water walls, super heaters, Repeaters & Economizers tubes:
1. Check for possibility of local explosions and take preventive measures for
recurrence.
2. Check for expansion obstructions
3. Contact BHEL for review of design
1. Check for any longstanding steam/water leakages from Hand holes etc.
2. Apply additional refractory for the affected position after consulting BHEL.
1. Check the operation of wall blowers and LRSBS. Reset the schedule to prevent
excessive deposits
2. Check the combustion parameters
3. Check the fineness of coal.
4. Check the healthiness of secondary Air damper system
1. Check for looseness of lock pins of all safety valves which can lead to falling
of lock pins
2. Replace the lockpins after proper setting of upper and lower rings.
1. Check for disturbed lift collar position. Check for missing lock pin of lift collar
2. Check for loose locknut of pressure adjusting nut
3. Reduce the pressure till the safety valve resets
4. Correct the lift collar, pressure adjusting nut positions
5. Refloat the safety valve
1.2.3.3. Valve is too hard to open/close:
1. Check for proper use of limit switch/torque switch depending upon the
application and type of valve
2. Check for proper setting of limit switch/torque switches
1.2.3.7. Torque switch operates while trying to open the valve from close
position (Gate valves):
1. Set the open torque switch value more than that of close torque switch
2. Bypass open torque switch with close limit switch contact for 5% travel of the
stem in the open direction
3. Check for jamming of the wedge
1. Check whether cover is fixed properly with proper `O’ ring/gasket and fixing
bolts
2. Service/replace the limit/torque switches and other components
Check for leakages/back charging from the cavity of motor towards purge
water line
Check for leakages in the impulse piping of cavity water pressure
Check for external leakages/tube leakages of the motor coolers
Check for accidental opening/passing of drain valve of purge line before
motor
Check for failure of cooling water to motor coolers
Check for leakages from the bushings
1.2.4.4. High differential temperature across the pump (with pump not in
operation):
1. Open the warm line and wait for reduction in differential temperature
2. Check for plugging of warm up line
1. Ensure that the DP across the strainers is less than 100 PSI (6 Kg/cm2 approx.)
under all operating conditions.
2. Arrest any leakages in the purge line system
1. Check for choking of filter element. Clean filter element, if necessary, replace
it.
2. Check the healthiness of diaphragm
1. Check for any loose connections and the availability of curent signal
2. Check for availability of instrument air at proper pressure
3. Check for calibration of the I/P Converter
4. Check for choking of Flapper/Nozzle assembly and Control relay
5. Check for any air leakages downstream
1.2.6.1.3. Soot blower valve head does not close after blowing:
4. Check for lance tube fouling with boiler tube or wall sleeve.
5. Check whether scrapper plate bolt is broken .
6. Check oil level in gear box
1. Check whethert lance tube is fouling with boiler tube or wall sleeve.
2. Check the tightness of gland bush /gland packing.
3. Check the setting of overload relay/MCC.
4. Check the accumulation of dirt over the rails.
5. Check the motor for insulation & winding .
6. Check the cables for any damage.
1. Check for any obstruction of travel carriage in housing
2. Check for proper chain tension
1. Check the blowing pressure & verify whether valve opening bolt is available.
2. Check the operation of valve stem.
3. Check the flue gas temperature for any increase.
4. Check whether flow protection is in service
1. Check the quality of packing, tightness, wear & tear of glands etc.,
2. Check the feed pipe for any surface defects such as scratches, dents etc.
1.2.7.1. Heavy passing of control valves:
1. Check the healthiness and position of burner tilting system. Bring the tilts
down
2. Check fineness and proximate analysis of coal
3. Check the proper functioning of spray flow meter
4. Increase wall blowers operation frequency
5. Reduce excess Air to the rated value
6. Check windbox/primary air pressure
7. Operate lower elevation mills
8. Tune Automatic Superheater/Reheater temperature control
1. Clean the strainer to ensure proper flow and to reduce grease before strainer
2. Ensure proper viscosity of grease. Ensure heater is switched `ON’ wherever
provided
3. Check & service grease distributor
4. Check and clean Nozzles.
1. Ensure free rotation of the pump
2. Ensure proper grease level
3. Ensure proper viscosity of grease.
1.2.8.1.11. Air pressure too low/no pressure (with gear lubrication system):
Reduction in Mill output :
1. Fires can take place due to accumulation of coal in reject chute, classifier,
Mill inlet duct, Hot air box, feeder etc.
2. In case fire is detected, authorised person has to decided whether preventive
action is to be taken while millis in operation or OFF line.
3. Prevent accumulation of coal in the above mentioned areas
4. Inspect and clear classifier, reject chute, clack box, mill inlet ducts, feeder,
Hot air box, feeder etc. periodically
5. Check the healthiness of screw conveyor periodically
6. Avoid single end operation of mill
7. Keep the mill on barring gear, especially when mill is hot
8. Prevent entry and accumulation of water into the mill
9. Check liners and ball charge periodically
10. Check the healthiness of instrumentation like mill leve, noise level,
pressure/temperature/flow instruments etc.
11. Maintain proper mill level
12. Check the operation of screw conveyor periodically
13. Ensure non-accumulation of coal in coal piping
1.2.8.1.23. Noise level not showing properly and not conforming to Mill level:
1. Check the location of the Microphone Relocate it, if necessary, as per BHEL’s
instructions.
2. Segregate the balls and take out balls of size below 20mm
3. Recalibrate the Noise level (100%) with full ball charge and with mill without
any coal. This can be done after segregation of undersize balls and
recharging the required quantity of balls.
4. Replace/repair the fault electronic cards of the noise level instrument.
1. Check for Air leakage through Dust guard/Mechanical face seal into gear box
2. Check for damages of mechanical face seal/Dust Guard Seal
3. Check for opening of upper bearing cover
4. Check for oil cooler tube puncture
5. Check for excess oil level in mill base
No return oil from vertical shaft upper radial bearing (Internal Lubrication
Mill)
1. Check for healthiness of rolls and then clearance with respect to Bowl
2. Check the wear out of Bull Ring segment, Bull Ring segment, worm wheel,
Bowl extension ring etc.
3. Check for the Jammed rolls
4. Maintain proper air flow
5. Check for water ingress along with coal
6. Check for pyrites along with coal
7. Check for damaged vane wheel assembly
8. Check the clearances between vane wheel w.r.t. separator body
9. Avoid over-loading of Mill
10. Maintain proper Mill outlet temperature
11. Reset Ring roll clearance, Journal head and Pr Spring seat clearance
12. Check Journal spring compression
13. Check the setting of the classifier
Mill Fires :
Vertical shaft failure :
1. Check for improper surface contact between bull ring and bowl
2. Check for heavy foreign material ingress in mill
3. Check for excessive wear of bull ring
4. Check for any mill fires
5. Check for material quality
1. Check the quality of oil and replace the oil id needed
2. Check the quality of the bearings
3. Check the bearing housing damage
4. Check for improper installation methods
5. Check for excessive backlash in worm gear
6. Check for improper matching of worm and worm gears
7. Check for damage of thrust bearing spring
Frequent Oil Filter choking :
1. Check for adequate compressed air pressure and also clean air filter.
2. Check that compressed air is free of moisture & mechanical impurities
3. Arrest leaks in compressed air tubing and also signal air tubing
4. Check for synchronised installation of the sections of each corner burner
tilting mechanism
5. Check for failed shear pins
6. Check for distorted coal and air buckets (tips) in shut down
7. Check for fouling of coal, air nozzles in shut down
8. Check for damaged oil gun/flame scanner assemblies in shut down
9. Check for centering and proper clearances of coal nozzles and buckets in
shut down
10. Check for damages of linkage mechanism during shut down
11. Check for proper alignment of power cylinder with burner tilting mechanism
12. Do not exceed design firing rate per elevation
13. Lubricate in pins of linkages and coal/air buckets during overhaul
14. Check the connected control system
1. Check for proper velocities of coal/air mixture. Carryout clean air flow
test/hot traverse
2. Check the erosion properties of coal
3. Carry out hard facing of coal nozzles/buckets/burner panels etc. in
consultation with BHEL
1. Check for full opening of mill outlet gates
2. Check for full opening of isolating gates at burner inlet
3. Check for coal deposits in coal pipes
4. Ensure purging of all four pipes during every start up and shut down of mills
5. Check for proper closing of purge air dampers (for tube mills) during mill
operation
6. Check for erosion of orifices in coal pipes. Replace them
7. Carry out clean air flow test and ensure that variation in flow through four
coal pipes is within limits
1. Ensure proper PA flow through coal pipes to avoid setting of coal dust in coal
pipes
2. Ensure purging of all four pipes with adequate PA flow during every start up
and shut down of mills
3. Maintain adequate mill outlet temperature
1. Check for proper line up of the system i.e. the required valves are open.
2. Check whether strainers are clean
3. Check for adequate level in LDO/HFO tank
4. Check for proper setting of pumps relief valve
5. Check for optimum opening of pressure control valve and proper functioning
on auto
6. Check for proper functioning of team tracing / electrical heat tracing for HFO
system
7. Check for adequate temperature for HFO system
8. Check for any air pockets in the system. Vent out air from filter vents
9. Check for DP across filter
10. Check for water contamination in HFO system
11. Check for mechanical impurities in HFO system
12. Check for solidification/choking of oil in the lines
1.2.11.1.2. HFO(LSHS) circulation from FOPH to boiler and back not getting
established:
1.2.12.1. Excessive Air leakage from Air side (Primary/Secondary) to Flue Gas
side
1. Check the quality of lub oil. Check for water/mechanical impurities in lub oil.
2. Ensure cooling water availability to lub oil coolers
3. Check whether lub oil pumps not operating/pumps not developing pressure
leading to no lub oil circulation
4. Check for excess hot air leakage around the bearings. Arrest the hot air
leakage
5. Check for damaged bearings
1. Check for Air entry into lub oil system on the suction side of the pumps
2. Check for the quality of oil. Replace lub oil if necessary
1.2.12.10. Increase in gas outlet temperature and steady fall in Air preheater
outlet temperature.
1. Check for dampers position. One or more dampers might have closed.
2. Check for rotor rotation. Check for rotor stoppage alarms.
3. Isolate the Air preheater in case rotation stopped
1.2.12.11. Excessive pressure build up/No pressure build up of lub oil pumps:
1. Check Air leaks/flue gas leaks over the pin rack. Arrest the leakages
2. Replace the damaged pin rack
1.2.12.17. Oil deposits in heating elements, especially in cold end baskets:
1. Check the looseness of bearing pedestal bolts, impeller hub bolts, blades
fixing bolts, coupling bolts etc.
2. Check proper seating of lub on shaft flange
3. Check whether any balance weights of the blades fell down
4. Check whether the blades are installed serially as per the punch marks and
of the same series.
5. Check whether there are deposits over the impeller, over the blades, etc.
6. Check the alignement with motor
7. Check for any abnormal sound from the bearings of Fan and Motor
8. Check for any temperature rise of the bearings.
9. Carryout vibration analysis to pinpoint possible reason.
10. In case it is unbalance, carry out balancing to correct the vibrations
1. Check that lubrication is proper. Check oil level, flow, pressure etc.
2. Check the functioning of lub oil system and cooler.
3. Check the quality of oil and impurities in oil (Moisture/mechanical impurities)
4. Check for bearing damages
5. Check alingment
1. Check that the speed of the actuator is matching with that of servomotor
2. Check the position of manual recirculation valve
3. Check the setting of pressure relief valve
4. Check for leakages in the servomotor and control oil system
5. Check the N 2 pressure in accumulator
1. Check the cooler for any lube leakages, by HT Rectify the leaking tubes
1.2.13.2. PA Fans:
1. Check the looseness of bearing pedestal bolts, impeller hub bolts, blades
fixing bolts, coupling bolts etc.
2. Check proper seating of hub on shaft flange
3. Check whether any balance weights of the blades fell down
4. Check whether the blades are installed serially as per the punch marks and
of the same series.
5. Check whether there are deposits over the impeller, over the blades, etc.
1. Check that lubrication is proper. Check oil level, flow, pressure etc.
2. Check the functioning of lub oil system and cooler.
3. Check the quality of oil and impurities in oil (Moisture/mechanical impurities)
4. Check for bearing damages
1. Check that the speed of the actuator is matching with that of servomotor
2. Check the position of manual recirculation valve
3. Check the setting of Relief valve
4. Check for leakages in the servomotor and control oil system
5. Check the N 2 pressure in accumulator
1. Check the cooler for any lube leakages, by HT Rectify the leaking tubes
1.2.13.3. ID Fans ( Radial Fans – NDZV Type) :
High Vibrations :
1. Check for any looseness of bearing pedestal bolts, impeller hub bolts,
coupling bolts etc.
1. Check the correctness of lubrication. Check oil level, flow, pressure etc.
2. Check the functioning of lub oil system and cooling water system
3. Check the quality and impurities in oil (moisutre/mech impurities)
4. Check for bearing damages and clearances
5. Check alignement
6. Check for any mechanical rubbing
1. IGV inoperative
2. VFD/Scoop tube inoperative
3. Check inlet/outlet gate
4. Check other gates/dampers of the gas path
5.
1. Check the cooler of the lub oil system for any leakages
2. Check for water leakages in the Fan bearings, lub oil tank
Heaters are not operating :
1. Check for S&T settings in the Electronic Controller and adjust, if needed
2. Check for excessive current settings
3. Check for any loose connections at transformer HT side, including
disconnecting switch.
4. Check for snapped emitting electrodes and collecting to emitting electrodes
gaps in shut down
5. Check the functioning of rapping system
6. Check the functioning of ash disposal system and overfilled hoppers.
Ensure that `start’ command is issued from the panel. Reset alarms on Control
desk.
Check MCC and LPB status
Check healthiness of motor and switch gear
1. This happens if `low pressure’ alarm does not reset even after 10 minutes of
pump running or if the pump continues to run beyond 10 minutes.
2. Check that the pump actually runs and develops pressure.
3. Check the N2 pressure of accumulator
4. Check the healthiness of bladder of accumulator.
5. Check the pressure switch settings and wiring.
6. Check for heavy leaks.
1.2.16.2. Servo Units:
Check drive card outputs i.e. 48V to blocking unit and +/- 10 to 15V to servo.
Check tightness of connections to the servos
Check the healthiness of the coils after switching off the drive card
If these are OK the problem is in the hydraulic elements. Ensure proper oil
supply to the valve and the position of the throttle valve in drain.
Check the valve operation from manual hydraulic lever
Check the filters and replace if needed
1. Check if any scanners are detecting or are on the verge of detecting flame.
2. Check that all fuel valves/gates are closed and correct feedback is available
at the respective panel as well as at the unit panel.
3. If SADC was in auto earlier, it might have reverted to too low opening. Confirm
its position.
4. Adjust the air flow suitably and ensure its permissives are available steadily.
5. Confirm that the burner tilt is normal (horizontal)
1.3.1.2. OIL FIRING
1. Check that all permissives are available at the respective panel. Check the
isolating valves feedback.
2. Check for proper voltages.
3. Check the healthiness of the coil.
4. Confirm that no other trip commands (software as well as hardwired) are
present.
5. Check proper air supply at the field. Ensure that there are no leakages.
6. Check the filter and air lock relays.
7. Check the position of the speed adjusting valve.
8. Check the solenoid valve for proper port change over.
9. Check the valve & actuator for leaks, punctured diaphragm, mechanical
obstructions etc.
1. Confirm the pressure of fuel and atomizing media and the fuel temperature in
case of heavy oils.
2. Check for restricted opening of the valves.
3. Check for possible choking of the gun.
4. Check that scanner supply is ON and settings are in order.
5. Check the ignitor for proper travel and spark.
6. Visually check the nozzle and flame from opposite corrner.
7. Maintain the windbox pressure, differential pressure and proper opening of
corresponding auxiliary damper.
8. Check the healthiness of the electronic modules and field inputs.
1.3.1.3. COAL FIRING
1. Confirm how far the start sequence proceeds and where it gets blocked.
2. Check the interlocks of individual steps.
check for healthiness of control panel cards , communication and data integrity.
1. Check open interlocks are present (e.g. all PA/ coal dampers closed, ignition
permit OK, no mill trip etc..)
2. Confirm that no contrary commands are present.
3. Check card and voltage healthiness.
4. Check all 4 coils and feed backs are properly looped.
5. Verify actual operation of all the dampers from local. Ensure full opening.
6. If any damper is not operating attend the same. (Refer section on pneumatic
devices.)
7. Check the limit switch and its wiring.
1.3.1.4.3 Sequence interruption due to problems in Seal air fans and its
dampers
1. Confirm that the seal air fan starts on Auto. Otherwise start it
manually.
LP lubrication not OK
the cooler.
1. Check the proper line up of the equipments like MCC, EPB, filters, coolers etc..
2. Confirm that the pump starts on command.
3. Check the oil flow is sufficient. Check the flow switches and their feed back
loop.
4. Confirm the availability of the standby pump in auto.
1. Check all permissives and trips (lubrication OK, bearing temp OK, ignition
permit Ok, status of aux motor and brake, seal air DP etc..)
2. Check for any hard wired or electrical trip commands.
1. Ensure the remote start permits like ignition permit, no mill trip, outlet gate
open, outlet temperature OK, coal on belt , feeder inlet gates open
2. Check for presence of any hard wired trips.
1. Check that remote and coal on belt feed backs are received.
2. Check that the feeder local panel power is ON and cards are in place.
3. Check that the status l.e.d on FRC card is lit and no LED are lit on LCA card.
4. If any lamps are ON in LCA, find out the defective component / card and
attend.
5. Check for feedrate error alarm.
1.3.1.6 FLAME SCANNERS NOT DETECTING
FLAME
1. Check the signal to the output cards separately and establish it.
2. Check the output cards separately.
3. Check the field cabling for earth faults, short circuits and proper
polarity.
4. Check for any overriding protective interlocks ( e.g, ID-FD fans off, MFT,
furnace to WB DP high.)
1. Check the inter locks of the valve (typically steam parameters OK, control
valve closed, bypass valve open )
3. Check the control relay loop. (Output card, wiring, interposing relays etc)
1. Check the interlocks are OK. Typically these are isolating valve open, down
stream temperature not very high, upstream parameters are OK.
2. Check the drive card healthiness.
3. Check the output and feedback loops are healthy.
4. Confirm that the fail safe air lock solenoid is energised. Check the relay and
field wiring and voltage.
5. Confirm that the valve is lined up properly. (Check air supply, filter, air lock
relay, leakages, wiring etc)
6. Check the valve operation locally.
1. Check the pressure and temperature measurement loop.
2. Check the individual valves operation separately.
3. Check the valve calibration.
4. Check for any auto blocking inter locks.
1. Check for any inter turn short or phase short circuit in rotor winding
2. Check the cable connections at the terminals
3. Check the healthiness of starter
1. Check for water ingress points into the motor and arrest them
2. Check for accumulation of water at the bottom of the motor
3. Check for any leakages in the cooler
4. Ensure closure of cooling water to motor, when motor is not running to
prevent moisture condensation inside the motor
5. Check for the healthiness of the winding
1.4.2.4. Output Voltages builds up, but DC ammeter does not read (no current)
1.4.2.5. Low precipitator Voltage:
1.4.2.9. Current shoots up as soon the HT is switched `ON’
2.1.2. Sudden total load rejection by opening of GCB but turbine & generator
remains in operation:
1. Check that DC lub oil pump and DC seal oil pump are started automatically
and the lub oil pressure/seal oil pressure are normal.
2. Start the DG set if not started automatically. Extend emergency AC supply to
all essential auxiliaries
3. Close main steam stop valves
4. Ensure that Reheaters are not pressurized
5. Prevent pressurization of condenser by closing all the steam drains to
condenser, if needed manually.
6. Monitor the coasting down of turbine
7. Perform manual barring, incase AC supply is not restored and AOP is not
started
8. Prevent hammering in piping by opening the respective atmospheric
vents/drains, manually.
1. Check that control valves/extraction valves are throttled to reduce steam flow
to turbine
2. Ensure that turbine is not overspeeded beyond the limits. If necessary trip the
turbine
3. Check that HP & LP Bypass valves are opened to control the steam pressure
4. Cut off Mills (Fuel input) immediately to reduce steam generator output
5. Maintain drum level, if necessary, manually
6. Maintain main steam/reheat temperature
7. Ensure all other parameters are within limits
8. Check that turbine exhaust steam temperature is within limits
9. Investigate the cause of load reduction.
2.1.6. Control valve/Stop valve fails to open after testing with ATT:
2.1.7. Failure of AOP and EOP and the turbine coasts down without lub oil
2.1.10. Leakage of oil from lubricating oil system with turbine in operation.
2.2.1.4.1. In pressure oil system during shut down of turbine generator unit:
5. Check temperature controller is `ON’.
6. Check the set point
7. Check positions of cooling water isolating valves for oil cooler in service.
8. Open the cooling water isolating valves, if closed or throttled.
9. Check for proper cooling water through oil cooler
10. Check vents, both cooling water side and oil side.
11. Check cooling water inlet temperature
1. Check that turning gear oil valve open & JOP ` ON’
2. Check for proper jacking oil header pressure
3. Check actual shaft lift oil pressures with set pressures. Correct pressure, if
necessary
4. Check clogging of JOP filter
5. Check leakage from hose connections of jacking oil lines
6. Check malfunctioning of pressure regulating valve.
7. Check oil temperature and maintain at 45 Deg.C.
8. Check using manual turning gear whether shaft turns easily
9. Check for any mechanical obstruction
If Turbine Casing temperature > limit temperature Let turbine cool down, run JOP
continuously till temperature comes down. Rotate the shaft by 180 Deg. through
hand barring.
1. Check manual isolating valve in oil supply line of shut off valve is open.
2. Check the healthiness of filter in oil supply line of shut off valve
3. Check for any leakage in oil supply line of shut off valve
4. Check solenoid valves of emergency shut off valve for its smooth operation.
5. Release solenoid valves mechanically.
2.2.1.10 Test oil pressure built up during normal operation and turning gear
operation.
2.2.2 Control Fluid System (500 MW Unit) :
2.2.2.7. Control Fluid/oil leakage monitor responds:
2.2.4.1. Loud Noise and or the following operating parameters exceed their limits:
1. Reduce turbine speed to less than 400 rpm and eliminate shaft distortion
before increasing speed.
1. After finding out the stability limits, determine operating parameters affecting
vibration to aid to determining cause.
– Load
– Expansion
1. Start turbine very carefully to soaking speed. Soak until the steam admitted
begins to reduce temperature differentials before running up to rated speed.
2.2.6.1. Differential expansion of HP Turbine at front end high during non
steady state operation
2.2.6.2. Differential Expansion of IP turbine at rear end high during non steady
state operation
Check condition that was the reason for turbine trip locally or from control
room
Check the unit can be restarted.
– CV
– Convertor
1. Check the play in thrust bearing – find out cause of high thrust bearing wear
(axial thrust, damage, lack of oil)
2. Check bearing metal temperatures
1. Turbine generator unit must not be operated if main trip valves are not
functioning perfectly
2. Locate and repair fault immediately
1. Do not operate turbine generator unit if trip solenoids are not functioning
perfectly
2. Locate and repair fault
2.2.7.13. Both overspeed trips fail to operate during overspeed testing
1. Repeat testing by test oil pressure several times until turbine trips at normal
test oil pressure values
2. If the defective overspeed trip still does not operate satisfactorily operation of
the turbine generator unit must not be continued
3. Locate and repair fault immediately
4. Check speed indicator
5. (compare frequency of excited generator with system frequency by means of
synchronizing device)
6. Adjust speed indicator
1. Perform testing by test oil pressure, if testing by test oil pressure reveals that
the two overspeed trips respond at slightly staggered settings, no further
action is necessary
2.2.7.15. Overspeed trip operates at too high a test oil pressure when tested by
test oil:
2.2.7.16. Overspeed trip fails to operate when tested by test oil pressure
2.2.7.17. Overspeed trip operates at too low a test oil pressure when tested by
test oil pressure
1. Check speed indicator, whether speed is too high and generator is not
synchronised.
2. Check at normal speed
3. Check the drift of trip speed
2.2.7.18. One overspeed trip fails to operate when tested by test oil pressure;
test oil pressure maximum, second trip responds normally
1. Test intact overspeed trip daily by test oil pressure until fault can be corrected
at next opportunity.
2.2.7.19. Hydraulic low vacuum trip operates too early at too high a condenser
vacuum:
2.2.7.20 Protection systems operating at too high or too low limit levels:
it should be opened.
3. Check valves of standby exhauster fan is closed
4. Check any mechanical or electrical fault in the seal steam exhauster fan.
5. Check the seal steam pressure set point and correct it
1. Check for any problem on the basis of valve description and correct.
2. Check the module output to control valves
3. Check remote manual operation of the valve
4. Check if temperature protection acted.
5. Check manual operation of valve locally through pumps
2.2.9.1. L.P. Bypass Stop and Control Valves are not operating
2.2.9.1.2. Reheat pressure < constant pressure set point but > variable Pressure
set point
2.2.10.1. Stop valves fail to open:
Check for any air ingress from drains, stainer cover, pump seal, check for
sufficient sealing water, well vent to condenser should be opened.
Maintain adequate hot well level
2.2.12.2. Motor taking high current/vibration high/bearing temp.high
1) Check the grease in the bearings for quality and quantity
2) Check exhaust flap is free and opens with exht pressure as soon as the
pump starts.
Transmitters
2.3.2.2. EHC Failure:
1. Check the oil pump discharge pressure for seal steam control valve & Leak
steam control valve.
2. Check the cable connection between control panel and control valves.
3. Check the healthiness of seal steam control panel
4. Check the seal steam inlet temperature permissive
5. Check the cleanliness of filters in control valves & oil units
6. Check the healthiness of pressure transmitter signals.
1. Check the limit switches for all the stop & control valves
2. Check the control panel healthiness
3. Check the release available for starting
4. Check all the pressure switches for healthiness
5. Check all the solenoids for healthiness and operation
6. Check all the root valves are open
2.3.17. Control Panel MCB’s Tripping:
1. Check the voltage coming from battery or battery charger for permitted
tolerances.
2. Check for short circuit in panel racks.
3.1. Sparking of the carbon brushes at the rotor slip rings accompanied by
over heating of individual brushes and uneven wearing of slip ring surface
3.2. Ingress of seal oil into stator body indicated by liquid level detector.
cooler, if any.
5) Run the Dryers continuously till moisture level come down
6) Leakage of water from stator winding (applicable for THW generators).
Always maintain stator water inlet pressure about 0.5 Kg/cm2 less than H2
pressure.
Check and identify all external joints, flanges for any leakage
and rectify it.
Check for proper functioning of seal oil system
2) Check the gas cooler for any contamination, dirt inside the tubes.
1. Check all fuel lines after stop valve upto nozzle are filled
2. Check all purge drain valves for any passing or any valve is open
3. Check liquid fuel HP filter for proper venting
4. Check for proper operation of liquid fuel bypass valve
5. Check for proper liquid fuel flow feedback from flow divider
1. Check for any leakage of trip oil to stop valve (SRV/liquid fuel stop valve)
2. Check pressure switch for low fuel pressure at GT inlet for proper functioning
3. Check healthiness of flame scanners
1. Check any OFF base lub oil system trouble if firing liquid fuel
2. Check proper acceleration of GT
3. Check any change in control constraints in FSR control from the one specified
in control specification
4. Check proper functioning of inlet guide vane and position feedback LVDT
5. Check any hunting in supply fuel pressure while GT is accelerating
6. Check divertor damper and guillotine gate position for any exhaust pressure
high trip.
1. Check for healthiness of all exhaust thermocouples, compressor air inlet
thermocouple and compressor discharge thermocouple.
2. Check for almost equal pressure in all fuel lines to combustion chamber at
selector valve
3. Check for any choking of liquid fuel nozzle
4. Check for any passing of purge drain valve
5. Check for any combustion changer leakages
6. Check for any atomising air leakages
← AIIMS Recruitment 2019 for Asst Engineer/Jr Parts / Components of a Centrifugal Pumps →
Engineer/Steno | 110 Posts | Last Date: 23 April
2019
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