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    Unit Overhaul

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    Sam
    The document discusses the unit overhaul philosophy, planning, and processes for the 6x210 MW and 4x500 MW units at the Vindhyachal Super Thermal Power Project. It provides details on the types of overhauls, main areas identified for overhaul, duration and frequency. It also summarizes the objectives, aims, categorization, pre-overhaul activities, activities during overhaul, post-overhaul activities, improvements made, and long-term planning constraints.

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    Unit Overhaul

    Uploaded by

    Sam
    1K views23 pages
    The document discusses the unit overhaul philosophy, planning, and processes for the 6x210 MW and 4x500 MW units at the Vindhyachal Super Thermal Power Project. It provides details on the types of overhauls, main areas identified for overhaul, duration and frequency. It also summarizes the objectives, aims, categorization, pre-overhaul activities, activities during overhaul, post-overhaul activities, improvements made, and long-term planning constraints.

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    The document discusses the unit overhaul philosophy, planning, and processes for the 6x210 MW and 4x500 MW units at the Vindhyachal Super Thermal Power Project. It provides details on the types of overhauls, main areas identified for overhaul, duration and frequency. It also summarizes the objectives, aims, categorization, pre-overhaul activities, activities during overhaul, post-overhaul activities, improvements made, and long-term planning constraints.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    1K views23 pages

    Unit Overhaul

    Uploaded by

    Sam
    The document discusses the unit overhaul philosophy, planning, and processes for the 6x210 MW and 4x500 MW units at the Vindhyachal Super Thermal Power Project. It provides details on the types of overhauls, main areas identified for overhaul, duration and frequency. It also summarizes the objectives, aims, categorization, pre-overhaul activities, activities during overhaul, post-overhaul activities, improvements made, and long-term planning constraints.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
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    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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.

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    PLANNING OF UNIT OVERHAULS

    NTPC/VINDHYACHAL

    CLASSIFICATION OF PLANNING ACTIVITIES

    PRE OVERHAUL

    ACTIVITIES

    DURING OVERHAUL ACTIVITIES


    POST OVERHAUL ACTIVITIES

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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.

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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

    NTPC/VINDHYACHAL

    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.

    NTPC/VINDHYACHAL

    THANK

    YOU

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