NTPC/VINDHYACHAL

UNIT OVERHAULS 6X210 MW & 4X500 MW UNITS OF

VINDHYACHAL SUPER THERMAL POWER PROJECT,
NATIOANAL THERMAL POWER CORPORATION LTD., P.O. : VINDHYANAGAR, DISTT.: SIDHI (M.P.), PIN:486885

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UNIT OVERHAULS PHILOSOPHY

210 MW ( LMW ) UNITS

TYPE OF OVERHAUL

MAIN AREAS IDENTIFIED FOR OVERHAUL

PERIOD OF OVERHAUL

FREQUENCY

A X D

BOILER & AUX. TUR. BRGS. INSP. BOILER & AUX.

20 DAYS 21 DAYS

EVERY YEAR EVERY 3rd YEAR EVERY 6th YEAR

GENERATOR ROTOR THREAD OUT BOILER & AUX. 35 DAYS ALL TURBINE CYLINDERS O/H GENERATOR ROTOR THREAD OUT

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UNIT OVERHAULS PHILOSOPHY

500 MW ( KWU ) UNITS

TYPE OF OVERHAUL

MAIN AREAS IDENTIFIED FOR OVERHAUL

PERIOD OF OVERHAUL

FREQUENCY

E F G

BOILER & AUX. TUR. BRGS. INSPECTION BOILER & AUX. LP TURBINE INSPECTION

15 DAYS 25 DAYS

EVERY YEAR EVERY 3rd YEAR EVERY 8th YEAR

BOILER & AUX. 35 DAYS HPT / IPT O/H GENERATOR ROTOR THREAD OUT

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UNIT OVERHAULS - PHILOSOPHY

210 MW ( LMZ ) UNITS

TO CONTROL THE O&M COST FOLLOWING ARE THE ACTIONS: SEQUENCE OF O/H FOR THE STATION ARE SO ADJUSTED THAT NOT MORE THAN TWO MAJOR O/Hs (TYPE D) TAKEN UP IN A YEAR. WHENEVER TWO MAJOR O/H COMMENCES IN A STATION IN A YEAR, SITE TAKES DECISION, DEPENDING ON BOILER CONDITIONS, TO RESTRICT THE O/H DURATION OF BOILER SUITABLY TO 17 DAYS AND 15 DAYS FOR 200 MW AND 500 MW UNITS RESPECTIVELY.

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OBJECTIVES OF UNIT OVERHAULS

TO MAXIMIZE PLANT AVAILABILITY

TO MINIMIZE MAINTENANCE COST THROUGH OPTIMIZATION OF RESOURCE UTILIZATION TO CREATE SAFETY IN WORK, EQUIPMENT AND ENVIRONMENT

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AIMS OF UNITS OVERHAUL

TO IMPROVE AVAILABILITY OF EQUIPMENT & SYSTEM TO IMPROVE QUALITY & INSPECTION OF MAINTENANCE JOBS TO IMPROVE MONITORING & REPORTING OF O/H PROGRESS TO REDUCE OVERHAUL DURATION

TO IMPROVE THE RE-COMMISSIONING INTERFACE TO PROVIDE A RECORD OF WORK CARRIED OUT TO MINIMIZE ISOLATION RESTRICTIONS TO REDUCE DUPLICATION OF ENGINEERING EFFORTS TO ENSURE STATUTORY REQUIREMENT OF BOILER LICENCE

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CATEGORIZATION OF UNIT OVERHAUL PROCESS

PLANNING UNIT SHUT DOWN COOLING DOWN OF MACHINES DISMANTLING INSPECTION FOR CONDITION REPAIR & RECTIFICATION ASSEMBLY TESTING & INSPECTION REVIVAL OF EQUIPMENT & SYSTEM REVIVAL & RECOMMISSIONING OF UNIT

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IMPROVEMENT AREAS IDENTIFIED

BARRING GEAR STOPPAGE TIME CONDENSER VACUUM GENERATOR AIR TIGHTNESS TEST TIME AIR INGRESS IN BOILER SCOPE OF WORK OF GENERATOR OVERHAUL ELECTRICAL TESTING TIME REVIVAL TIME OF UNIT AFTER UNIT OVERHAUL-HFO CONSUMPTION SCOPE OF IN SITU TESTS DURING UNIT OVERHAUL SCAFFOLDING ERECTION & DISMANTLING TIME PERCENTAGE AREA OF TUBES COVERED FOR D-METERING BOILER SAFETY VALVES SETTING TIME

ULTIMATELY LEADING TO IMPROVEMENT IN PLANT AVAILABILITY, RELIABILITY & REDUCTION OF O&M COST

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PLANNING OF UNIT OVERHAULS

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CLASSIFICATION OF PLANNING ACTIVITIES

PRE OVERHAUL

ACTIVITIES

DURING OVERHAUL ACTIVITIES

POST OVERHAUL ACTIVITIES

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PRE OVERHAUL ACTIVITIES

PLANNING & APPROVAL OF EIGHT YEAR ROLLING PLAN OF UNIT OVERHAULS

PLANNING & APPROVAL OF NEXT FINANCIAL YEAR PLAN FOR UNIT OVERHAULS PLANNING & APPROVAL OF MAJOR WORKS TO BE CARRIED OUT DURING UNIT OVERHAULS IDENTIFICATION, REQUIRED QUANTITY PROJECTION AND REVIEW OF STATUS OF CONSUMABLES ( STOCK ITEMS) ON MONTHLY BASIS FOR UNIT OVERHAULS

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CONTD

IDENTIFICATION OF CRITICAL MATERIALS REQUIRED FOR UNIT OVERHAULS AND REVIEW ON MONTHLY BASIS. PREOVERHAUL MEETING FOR REVIEW OF CONSTRAINTS & PREPAREDNESS INVOLVING ALL. PRE OVERHAUL CONDITION MONITORING REPORT PREOVERHAUL UNIT SURVEY UNIT OUTAGE ANALYSIS FROM LAST OVERHAUL FEED BACK OF UNIT FROM FIRST SYNCHRONIZATION REVIEW OF STATUS & COORDINATION OF WELDING SUPPLY, LIGHTING, LIFTS, HOISTS, CRANES ETC.

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CONTD

PAST OVERHAULS AT A GLANCE (HISTORY OF UNITS) PREPARATION OF MILESTONES (PLANNED) COMPILATION OF UNIT DEFECT LIST PRE OVERHAUL SPRAY VALVES CHARACTERISTICS

WORK REQUIRED TO BE CARRIED OUT AS PER

OPERATION REQUIREMENT EFFICIENCY REQUIREMENT CHEMISTRY REQUIREMENT TRIPPING COMMITTEE RECOMMENDATIONS C&I REQUIREMENT

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CONTD

BOILER TUBE LEAKAGE COMMITTEE RECOMMENDATIONS OS RECOMMENDATIONS CONDITION MONITORING GROUP RECOMMENDATIONS

SAFETY REQUIREMENT
R&M REQUIREMENT

PREPARATION OF:
PTW & CLEARANCE BOOKS FOR BOILER & AUX.
PTW & CLEARANCE BOOKS FOR TG & AUX. CLEARANCE & RECOMMISSIONING BOOK FOR VALVES, DAMPERS, IGVs, SOOT BLOWERS & LRSBS

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CONTD... CHECK SHEET FOR MOTOR TRIALS, EQUIPMENT RECOMMISSIONING & PROTECTION CHECKING CHECK SHEET FOR VALVES REQUIRED FOR CONDENSER FLOOD TEST CHECK SHEET FOR VALVES REQUIRED FOR BOILER HYDRO TEST COMMUNICATION LOG BOOK

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DURING OVERHAUL ACTIVITIES

PREPARATION OF DISPLAY BOARD FOR COMMUNICATION OF OVERHAUL PLANNING COORDINATION IN ISSUE OF PERMITS

MONITORING OF WORK PROGRESS / COMPLETION

COORDINATION OF REGULAR UNIT OVERHAUL MEETING AT 5:30 PM IN O&M CONFERENCE HALL PREPARATION & DISTRIBUTION OF RECORD NOTES FEEDBACK TO WRHQ & CC-OS FOR WORK PROGRESS

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MONITORING & REVIEW OF CRITICAL VALVES STATUS AS PER CHECK SHEETS REQUIRED FOR CONDENSER FLOOD TEST & BOILER HYDRO TEST MONITORING & REVIEW OF CLEARANCES AVAILABLE & RECOMMISSIONING PROGRESS ( MOTORS TRIALS / EQUIPMENT TRIALS) COORDINATION IN FURNACE AIR TIGHTNESS TESTS CONDENSER FLOOD TESTS BOILER HYDRO TESTS

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POST OVERHAUL ACTIVITIES

PREPARATION OF UNIT-WISE UNIT OVERHAUL REPORT IN BOOK FORM HARD COPY FOR LIBRARY & ISO PREPARATION OF UNIT OVERHAUL REPORT IN CDFORMAT

POST OVERHAUL REVIEW OF WORKS PLANNED AND ACTUALLY COMPLETED.

POST OVERHAUL REVIEW OF IMPROVEMENT IN PARAMETERS & EFFICIENCY POST OVERHAUL PLAN Vs ACTUAL DEVIATION SHEET

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PROCESS IMPROVEMENTS
BOILER EXTERNAL WATER WASHING WAS CAUSING DAMAGE TO INSULATION AND DELAY IN START OF OVERHAUL ACTIVITIES, DRY BOILER CLEANING STARTED. QUICK ERECT SCAFFOLDING IS BEING USED FOR BOILER INTERNAL CLEANING & INSPECTION

HIGH PRESSURE WATER JET CLEANING IS BEING DONE

FOR BOILER TUBES

ALL PA FANS & MILL MOTORS VIBRATION MEASUREMENT

ALSO STARTED DURING UNIT OVERHAULS ALL HT MOTORS TRIAL RUN IS BEING TAKEN FOR 8 HRS AND LT MOTORS FOR 4 HRS

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PROCESS IMPROVEMENTS
CONDENSER TUBE CLEANING IS BEING DONE USING CONCO BULLETS INVOLVEMENT OF FQA IS INCREASED IN MAIN TURBINE & GENERATOR AREA

BOILER DRUM FILLING USING HOT WATER STARTED

BOILER TUBES D-METERING SCOPE INCREASED UPTO
25000 LOCATIONS. 24-VOLT HAND LAMPS ARE BEING USED PREOVERHAUL / DURING OVERHAUL SAFETY SURVEY BEING CARRIED OUT

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ADDITIONAL RESPONSIBILITIES
DRAWING SECTION: O&M DRAWING SECTION IS PIONEER IN DEVELOPMENT OF DRAWINGS IN AUTO CAD. MANPOWER : TWO DRAFTMENTRAINED IN AUTO-CAD PRINT ROOM: O&M PRINT ROOM COPE UP THE DAY TO DAY REQUIREMENT OF PHOTCOPYING, CYCLOSTYLLING & AMMONIA PRINTING OF DRAWINGS REQUIRED FOR INDENTING PURPOSES. MANPOWER: ONE ATTENDANT

DISPLAY ROOM: O&M DISPLAY ROOM LOCATED AT

SERVICE BUILDING O MR IS BEING MAINTAINED AND UPDATED REGULARLY

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LONG TERM PLANNING CONSTRAINTS

UNIT OVERHAUL REPORTS: INSPITEOF ALL BEST POSSIBLE EFFORTS, PROBLEM IS BEING FACED TO GET THE FEEDBACK FROM OTHER DEPARTMENTS FOR THE JOBS COMPLETED, MEASUREMENTS TAKEN AND EXPENDITURE INCURRED DURING UNIT OVERHAULS, WHICHCAUSES DELAY IN COMPILATION OF UNIT OVERHAUL REPORTS. OVERHAUL COST: PRESENTLY IT IS DIFFICULT TO GET THE FINANCIAL DATA i. e. UNIT OVERHAULS COST (THE EXPENDITURE INCURRED DURING RESPECTIVE UNIT OVERHAULS). CONTINUOUSLY THESE DATA ARE BEING ASKED BY CC & WR. ISSUE OF MATERIALS: MATERIALS PROCURRED FOR UNIT OVERHAULS MUST BE TAGGED BY STORES AND NOT TO BE ISSUED TO ANY OTHER DEPARTMENT WITHOUT CONSENT.

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THANK

YOU