DCR-27_01_2015

BHEL - PSSR CHENNAI: Staus of Units scheduled for Syn/CA in 2014-15 : AS ON 27.01.2015

Page 1 of 4

#

Ratin

g

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Load

(MW

)

STATUS / REMARKS

1 800 800### 0

31.0

5.12

Mar

.14

2 800 800### 0

Dec

-14

3 600 600### 0

10.0

8.12

Mar

.14

4 600 600### 0

10.1

1.12

Nov

.14

5 600 600### 0

11.0

5.12

Oct

.14

6 250 250### 0

16.0

9.08

7 500 500### 0

Nov

.14

PROJECT NAME Co

nt

Sync

/CA

P/A

Sync

/CA

MILESTONES

KRISH #1 COD Cont: 11.05.12 COD Plan: Nov 14

SCH

P/A

HT05.02.1

224.03.1

3

BLU13.03.1

213.08.1

3

SYN31.05.1

231.03.1

4

Unit-1 Boiler lighted up at 06:45 on 27.01.15 Mil-C hot air gate seal leak rectified with seals patch work by BHEL/Ranipet technicians.Mill ducts hot side A-E eroded portion patch work was done.

KRISH #2 COD Cont: 28.01.13 COD Plan: Mar 15

SCH

P/A

HT05.08.1

217.12.1

3

BLU18.09.1

222.06.1

4

SYN30.11.1

216.12.1

4

UNIT SYNCHRONISED FOR THE FIRST TIME AT 0054 HR ON 16.12.2014 AND LOADED TO 107 MW. Hot PA duct identified leaks are being attended. Mill F Dynamic classifier motor trial run is completed. Dampers & gates -145/176 commisioning is completed. ESP D pass, oil filtration is in progress, Field charging is planned today for the fields oil filtration is completed (6/16 nos.)JITPL #1 COD Cont:

26.08.12 COD Plan: Jan 15

SCH

P/A

BLU22.04.1

210.12.1

3

TBU09.05.1

209.07.1

3

SYN10.08.1

231.03.1

4

Generator compressor assembly work is completed. End-shield box-up (both TE&EE) completed. LP inner casing sealing strip fixing work in completed. LP Rotor 1&2 placed and alignment checked. LP-1 & LP-2 Roll check completed. HP-IP alignment completed, coupling in progress. LP 1 & 2 inner inner casing box up with heat tightening completed. LPT 1 inner outer casing box up in progress. Generator H2 cooler erection completed. Generator alignment with LP is in progress. Erection Completion for balance PG test points. Generator primary water flushing is in progress.

JITPL #2 COD Cont:24.11.12 COD Plan Dec '14

SCH

P/A

BLU22.07.1

202.08.1

4

TBU09.08.1

231.07.1

4

SYN10.11.1

210.01.1

5

Unit hand tripped at 0030 hrs on 25.01.15 due to no demand (grid restriction) . Main turbine is on barring gear. Second stage- lubes oil flushing for Mill 2H is in progress. ESP A Pass: First 14/18 nos Fields Charged. BHEL/Hyderabad engineer is at site for attending TDBFP-B servo motor rectification works. TDBFP- A is on barring gear .

MALWA #2 COD Cont: 11.05.12

SCH

BLU11.03.1

225.12.1

3

TBU11.02.1

218.09.1

4

SYN11.05.1

211.10.1

4

Unit is in shutdown condition since 1344 hr on 21.01.15 due to GT Y phase transformer fire accident. Draining of oil from GT Y phase commenced on 24/01/2015. Tender pertaining to restoration work of GT Y phase opened on 24/01/2015 and note with comparative statement has been sent HQ approval for release of WO. New GT has been dispatched from Bhopal on 23/01/2015 and is in transit.NEY #2

COD Cont: 14.11.08 COD Plan: Dec 14

SCH

P/A

TBU17.05.0

804.05.1

1

SYN16.09.0

823.11.1

4

CA16.09.0

8

UNIT REACHED FULL LOAD AT 0016 HRS ON 24.01.215 Unit present load 120 MW. Lignite transport conveyor B shear pin got cut. Being attended. On 26.01.2015 unit load was raised to 250 mw at 1900 hrs. Load reduced to 150 mw due to grid restriction. EBFP vendor reported site on 22.01.2015.Vendor attended the problem. EBFP run for 5 minutes at rated speed. Remote operation to be checked by vendor. Awaiting vendor to attend the issue.Antrieb actuator vendor is available at site

NTPL TUT #1 COD Cont: 28.04.12 COD Plan: Jan 15

SCH

P/A

BLU31.10.1

119.03.1

4

TBG30.12.1

120.07.1

4

SYN28.01.1

2Nov.14

Boiler DM water filling and draining is in progress to reduce the chloride level. Condenser rear water box manhole opened & defective tubes are plunged. C & S Vendor available to attend LT Modules Issues. Boiler Flame view system completed.


Page 2 of 4

#

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Load

(MW

)

STATUS / REMARKSPROJECT NAME Cont

Sy

nc/C

AP/

A Sy

nc/C

A

MILESTONES

8 500 500### 0

Jan-

15

9 500 500### 0

27.0

9.13

28.0

2.14

### 150 150### 0

### 150 150### 0

17.0

1.12

Oct

-14

### 150 150######

17.0

3.12

26.0

3.14 Unit is running at 136 MW.

### 150 150######

17.0

5.12

28.0

4.14 Unit is running at 146 MW.

### 150 150### 0

###

23.0

9.11

18.0

9.13

###

23.1

0.11

Jan-

14

###

23.1

1.11

Mar

-14

NTPL TUT #2 COD Cont: 28.09.12 COD Plan: Mar 15

SCH

P/A

BLU31.03.1

223.09.1

4

TBG31.05.1

2Dec.14

SYN28.06.1

2Jan-15

AOP 2 pump run for 4 hr with spare pump in presence of suppliers rep. Mill 2G & 2E Stage II Lube oil flushing is in progress. Boiler Flame view system work is in progress TD BFP 2A Oil flushing is in progress. LT O2 Analyzer 2/4 completed PA Fan 2A motor bumped and DOR checked ok.

VALLUR #3 COD Cont: 27.01.13 COD Plan: Nov.14

SCH

P/A

BLU27.05.1

231.08.1

3

BG27.05.1

214.02.1

4

SYN27.09.1

228.02.1

4

72 hrs full load trial operation completed and Unit was stopped at 1600 hrs on 10.12.2014 due to coal shortage. TG rolled to 3000 rpm at 1730 hrs on 14.01.2015 for checking the vibration behaviour of the TG after catenary correction & re alignment work and hand tripped at 1945 hrs due to clearance not available from the customer. Vibration levels were within the limit NTECL to give clearance for light up and HINDALCO 1

SYN Cont: SYN Plan: 2014-15

SCH

P/A

HT15.02.1

108.09.1

3

BLU29.05.1

124.08.1

4

SYN25.09.1

1Jan.15

PA duct insulation under progress. Feeders D & E calibration completed. Eco coil 100% RT and repair under progress. Mill CAFT is planned.

HINDALCO 2 SYN Cont: 25.12.11 SYN Plan: Oct.14

SCH

P/A

HT15.05.1

104.02.1

4

BLU29.08.1

113.05.1

4

SYN25.12.1

131.10.1

4

TG is on barring gear. Eco coil 100% RT and repair completed. Boiler Hydro Test was done at working pressure and identified leaks being attended. ESP internal inspection under progress with Ranipet engineer.Esp charging is planned.

HINDALCO 3 SYN Cont: 25.02.12 SYN Plan: Mar.14

SCH

P/A

HT15.07.1

103.03.1

3

BLU29.10.1

111.10.1

3

SYN25.02.1

226.03.1

4HINDALCO 4 SYN Cont: 25.04.12 SYN Plan: Oct.13

SCH

P/A

BLU29.12.1

110.05.1

3

SYN25.04.1

210.10.1

3

CA17.05.1

228.04.1

4HINDALCO 5SYN Cont: SYN Plan: 2014-15

SCH

P/A

HT15.11.1

118.07.1

4

BLU27.02.1

2Jan.15

SYN25.06.1

2Mar.15

TG lube oil flushing is under progress. Corners 3 & 4 ignitors, burners & scanner inspection completed. Right side wall blower internal clearance checking under progress. APH A trial taken for 15 min. Furnace ATT was done and identified leakaage being attended VFD transformer testing completed. Power supply is awaited from customer. MDBFP A Oil flushing under progress. PA Fan A oil flushing under progress. APH B oil flushing under progress. AC Scanner fan trial completed and scanner air line blowing completed. EDTA tank & pump erection completed.Motor trial run is planned.

...MRPL UB #1 SYN Cont: 23.11.11 SYN Plan: Sep.13

SCH

P/A

HT23.03.1

113.06.1

2

BLU23.07.1

127.07.1

3

SVF23.09.1

118.09.1

3

UB1 is in service at 185 TPH on master pressure control. 3 burners are in gas firing.

...MRPL UB #2 SYN Cont: 23.11.11

SCH

P/A

HT23.04.1

109.11.1

2

BLU23.08.1

113.11.1

3

SVF23.10.1

119.01.1

4

UB 2 is running at 180 TPH on master pressure control. 3 burners are in fuel gas.

...MRPL UB #3 SYN Cont: 23.11.11 SYN Plan: Mar.13

SCH

P/A

HT23.05.1

130.03.1

3

BLU23.09.1

104.01.1

4

SVF23.11.1

115.03.1

4

UB 3 is in shutdown for annual maintenance from 09/01/2015. Igniter seal air line modification completed. Burner spuds removed and stabilizer plates replacement completed. Fuel gas hoses awaited for further blowing and spuds erection.IRD engineer left site after modification of UB 3 VMS system. Fuel gas system valves stroking, limit setting in progress.


Page 3 of 4

#

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Load

(MW

)


Sy

nc/C

AP/

A Sy

nc/C

A

MILESTONES

###

### 20 20 20 0

23.0

4.11

26.0

1.13

### 30 30 30 17

28.1

1.11

26.0

4.13

### 29 29 0

23.1

0.11

30.0

4.14

### 29 29 20

23.1

1.11

20.0

2.14

###

...MRPL UB #4

UB 4 in service with 150 TPH on master pressure control. 2 burners on gas firing

...MRPL GT #1 SYN Cont: 23.04.11 SYN Plan: Jan.13

SCH

P/A

CES23.08.1

009.02.1

1

OFC23.02.1

117.02.1

2

SYN23.04.1

126.01.1

3

GT1 under shut down. Stopped due to lub oil tank level dropping. Oil level topped up. GT 1 was run for identification of oil leakage. Oil leakage observed from hydraulic oil line to IGV, union leakage. Gt 1 stopped for attending the same. HRSG 1 under shut down. Economiser vent leakage observed, being attended. GT 1 inlet air pulsating system logics implemented in HRSG 1 PLC and taken in to service. Diaphragm valve passing is observed in around 5 SOVs. Matter is being referred to vendor. Water injection pump vendor M/s Sulzer visited and pump dismantled for jamming problem. Balance drum area scoring and jamming observed. Shaft found run out 0.17 mm. Shaft to be replaced.

...MRPL GT #2 SYN Cont: 28.11.11 SYN Plan: 26.04.13

SCH

P/A

CES23.03.1

117.02.1

1

OFC23.08.1

120.02.1

3

SYN28.11.1

126.04.1

3

GT 2 in service with 17 MW load. HRSG 2 in service with 35 TPH. Exhaust frame cooling blower 2 balancing in progress.

...MRPL STG #1 SYN Cont: 23.10.11 SYN Plan: Apr 14

SCH

P/A

TBU23.06.1

1

BG23.09.1

126.02.1

4

SYN23.10.1

130.04.1

4

Under shut down due to vibration problem. Turbine assembly activities in progress. Lubroid packers in place of earlier spherical washer arrangement supplied. Packers were further machined after centering of rotor with pedestals. Blue matching of packers completed. Eccentric guide lapping completed. Flow path clearance checking completed. Turbine casing boxed up and parting plane bolts tightening completed. VHP inlet flanges tightening completed. Alignment reading taken, to be corrected. Gearbox to generator decoupled.Alignment reading taken, to be corrected. Gearbox to generator decoupled. Alignment correction in progress. IP interconnection piping erection completed. Front bearing instrumentation works in progress. TD CEP planned for startup.

...MRPL STG #2 SYN Cont: 23.11.11 SYN Plan: Feb.14

SCH

P/A

TBU23.07.1

1 `

BG23.10.1

125.11.1

3

SYN23.11.1

120.02.1

4

STG 2 is tripped on 23.01.15 on thrust bearing RTD failure. Restarted and resynchronized same day night by 2200hrs. Delay in restart due to LP control valve oil leak from seals. Valve replaced from STG 1.

...MRPL - BOPGBC

GBC and fuel gas system: GBC 2 final alignment completed. Dry gas seals vendor at site for seals assembly. BHEL Hyderabad Engineer reaching site today. Suction leak test with MRPL completed. GBC-1 suction and discharge HT completed. Cardboard blasting completed. Alignment with piping in progress. MRPL operation punch points being attended.


Page 4 of 4

#

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Load

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Sy

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MILESTONES

###

# PROJECT NAME Rtg Ld REMARKS

1 ### 0

2 ### 0

3 ###### Unit is running at 520 MW after attending the Boiler tube leakage.

4 ### 0

5 ######

6 ######

3050 1404

CC: ED/SR

...MRPL - BOP

COMMISSIONING CERTIFICATE FOR ALL THE PACKAGES RECEIVED FROM MRPL ON 19/01/2015.BOP: TDBFP 1 MOP in service from 17.01.2015. TDBFP 1 was started and tripped on thrust bearing temperature high. Oil flow orifice found interchanged and was corrected. Discharge valve gearbox was broken and is replaced. Discharge flange leak being attended. TDBFP 2 tripped on control oil pressure low on 13.01.2015, AOP tripped on overload, pump bearing found damaged. Bearing is received and replacement is planned. ACW and CW system in operation with motor driven pumps. TD CW pump turbine rotor sent on 20.12.2014 to M/s KEPL works for metal build up and machining. Offer for repair received after their inspection, order placed on 12.01.2015. Expected by 30.01.2015. LCO centrifuge# 1 found seal breaking, taken up with BHEL Hyderabad for vendor deputation. Deaerator 1 isolated for shut down activities. BHEL Hyd engineer at site for attending to water carryover problem from air vents. Vent pipe incomplete welding observed, trays removed for rectification. Vendor at site from 22.01.2015. Balance platform/approach erection works in progress. (22 balance out of 145) M/s Areva vendor is available at site for commissioning of Data concentrator system. TD IFO pumps hunting problem could not be resolved by service engineer at site. Suspected due to low lift operation and taken up with vendor/ BHEL, Trichy. Steam control valve internals will have to be replaced. WO for Throttle Valve released by BHEL/Trichy. Vendor has indicated 18 weeks delivery. Expected by end of April 2015. Commissioning exception list points being attended. Surface condensate control valve commissioned and control loop put in auto. LP Heater inlet control valve stuck. IL Palakad rep at site for servicing the control valve.

MALWA #1

Unit is under Shutdown . GT all 3 nos New HT bushings of Alstom make were erected on 24 &25 Jan 2015.Final connection of lead to be completed after draining of oil from GT tank. Activity to continue from 27/01/2015. AH SB runner plate despatched from ranipet on 24/01/2015 and is in transit. Gen core looseness checks completed and protocol signed . Gen rotor was inserted on 25/01/2015, further erection works like end shield fixing, erection of TE and EE seal body , exciter components erection to continue

...NCTPS #1

On 07.11.2014, Unit was running at 573 MW continuously. At 14:04 hrs, Unit got tripped due to heavy fire and vibration in IPT rear bearing area. LPT-2 rotor fins cutting completed. LPT-1 & 2 arrangements for trial box-up are under progress. HP inner casing withdrawl under progress. Generator end shield assembly is in progress.

...NCTPS #2NEYVELI #1

Unit is under shutdown since 06.01.2015 for attending rear pant leg PA wind box steam leakage, FBHE 3 and 4 top bed material leaks, PA control damper jamming issue. Hydro test completed successfully on 26.01.2015 at 150 ksc. Unit light up plan today.

VALLUR #1

Unit is running at 454 MW. Pumps PG test is completed.

VALLUR #2

Unit is running at 430MWTG PG test: one set of Trial reading taken at full load on 24.01.2015

TOTAL

// GM (TSX)

AS ON 27.01.2015

Documents

DCR-27_01_2015