QUALITY CHECKS DURING O/H

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QA in different areas during O/H

Boiler Pass 1&2 Ducts Rotary parts ESP Turbine auxilaries Generator
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24 May 2012

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ROLE OF QUALITY ASSURANCE DEPT. AT SITE:

TO TO TO TO TO PREPARE QUALITY PLAN BEFORE OVERHAUL. PREPARE QA CHECK LISTS. INVOLVE IN CRITICAL CHECKS DURING OVERHAUL. INVOLVE IN DAY TO DAY MAINTENANCE. CARRYOUT NON DESTRUCTIVE TESTING.

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Boiler pass 1 & 2 (Tube Failure Mechanisms)

Erosion Corrosion Mechanical wear Material mix-up Weld failures i.e Dissimilar & attachment weld failures

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Preventive measures during O/H

100% visual inspection in all the identified areas Deploying IBR qualified welders & use of approved electrodes Extensive Tube Thickness survey NDT of welds( DPT, RT, UT &MPI)

24 May 2012

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QA methodology in different areas

Goose neck region: DPT, Visual inspection and TTS RH girdling loops: Visual inspection for dents and distortion of binding loops Economisers & LTSH: TTS for top, bottom, extreme coils both Sides 1 to 5 tubes and visual inspection for alignment and erosion.

24 May 2012

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QA methodology in different areas

LTSH bifurcation tubes: Visual inspection for refractory damage and erosion & TTS RH : Visual inspection for overheating ,cleat rubbing (half reheater) and TTS & DPT Header stub joints: Visual inspection and DPT Screen tubes: TTS and visual inspection Raiser tubes: MPI / RT of bends and weldments

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MPI of critical piping

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DUCT AND APH

DUCT:
Deflector plates, damper gates, Duct bend portion eco outlet hopper :

Visual inspection for erosion & Cleaniness. Rotary parts: I APH: 1. Guide bearing : Visual inspection and level checking 2. Support bearing: visual (wear & tear on runner area)

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PA Fan support bearing inspection

24 May 2012

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FANS AND ESP

II PA Fan, FD Fan:
Blade alignment and clearances, motor & fan alignment and blades DPT III ID Fan: 1. Bearing surface Visual & DPT 2. Shaft visual inspection for pitting 3. Welding joints and shaft- MPI&DPT

ESP:
Erosion of emitting electrodes, hammer Rings, bending of shock bar and cracking of suspension frame hooks of collecting electrodes.

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ID FAN Shaft welding DPT

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PENETRANT APPLICATION

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READY FOR INSPECTION

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TURBINE
Main turbine (HP,IP and LP) checks NDT checks on turbine and auxilaries Generator checks NDT on generator Other checks in different areas

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TURBINE CHECKS
Radial alignment Axial alignment Clearances measurement Coupling run out

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NDT on Turbine and Auxiliaries

Visual inspection Blue matching of valves DPT & MPI of components UT of bearings

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VISUAL INSPECTION
Turbine blades, De aerator perforated sheets, rotor alumina blast cleaning Shafts of CEP,BFP and vacuum pumps HRH & MS strainers Valves seating area

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Blue matching of valves

Line contact to be ensured

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DPT and MPI

Shafts of CEP,BFP and Vacuum pumps MS & HRH strainer line weld joints, control fluid oil line weld joints, impulse line weld joints TDBFP gear coupling , bearings babbit metal area. Stop valves & control valves components MPI of rotor & blades

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DPT of turbine bearings

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UT of bearings
To assess the de-bonding of babbitting Reference Standard: ASTM A 435 Acceptance norms: No multiple backwall echos
UNIT 4 Brg Thrust pads-36 Nos

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Eddy current testing on condenser tubes

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GENERATOR CHECKS
After rotor threading out-rotor N2 pressure test(leakage - Not morethan 0.5 kg/sg.cm for 6 hrs) IR value of rotor RSO test of rotor( sinusoidal wave form) Winding resistance

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GENERATOR CHECKS
Stator Visual inspection of stator IR value of stator Wedge tightness , ELCID test and tan Winding resistance

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GENERATOR CHECKS (NDT on Generator)

DPT of compressor blades UT & DPT of gen. retaining rings (ASTM A435) DPT of seal oil system weld joints Completion of protocol before rotor threading in. IR values of Gen. Bearings

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DPT of compressor blades

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GENERATOR CHECKS
(CONTINUED..)
Compressor Hub And Baffle Ring Carrier Radial & axial Clearances( min.1.8) Radial alignment of GEN-Exciter and correction Axial alignment & Exciter Swing check CRO readings of gen. exciter Hydro test of H2 coolers and exciter coolers Gen. casing pressure test( 4 kg / sq.cm)

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Other areas
DPT of expansion bellows DPT of HP heaters parting plane welds Condenser cleaning Deaerator visual inspection

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THANK YOU

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