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Power Sector Western Region Technology Day 11 th May 2009.

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Presentation on theme: "Power Sector Western Region Technology Day 11 th May 2009."— Presentation transcript:

1 Power Sector Western Region Technology Day 11 th May 2009

2 Power Sector Western Region TECHNOLOGICAL TOOLS

3 Power Sector Western Region Use of Electrical Torque wrench for Tightening Boiler Structure Bolts At 1 x 500 MW Khaperkheda

4 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 4 Cycle time reduction in tightening boiler structure bolts Background  At boiler erection site thousands of BOLTED JOINTS are to be tightened MANUALLY using DE Spanners for snug tightening & Torque tightening by trip torque type long handle torque spanner.  The process of bolting arrangement consumes enormous time for achieving desired results, including uniform tightening & ensuring a designed torque value.  This process was identified for taking up Improvement project because of the following being repetitive in nature time consuming labour intensive having substantial amount of preparatory work to be done before the starting actual process (set up time) high level of risk involved (some locations for actual work place are above 80 meter above ground level & are to be performed on temporarily erected scaffoldings

5 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 5 Objective  Reduction in time taken for complete bolting arrangement necessary for a 500 MW Boiler erection (at Khaperkheda site about 40, 000 no. M24 Bolts of lengths 70 – 160 mm are used)  Ensuring designed tightness of bolting arrangement without further need of cross checking by Quality representative  Safer working conditions for Operator Cycle time reduction in tightening boiler structure bolts

6 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 6 Evaluation of alternatives 1. Pneumatic torque wrench  Benefits Available with leading hand tool manufacturers like Bosch, Ingersoll Rand & others. Widely used in manufacturing plants (automotive assembly lines) where high turnover per day is the hour of need (but here the Operator has a fixed place & jobs move to his operating area one after another). These wrenches are comparatively lighter.  Drawbacks for us Difficulties in ensuring dry air to the wrench in all weather conditions Maintaining desired air pressure at a long distance through a compressor Requirement of supports since length of air pipes may extend up to 100 meters Thus making the whole arrangement very clumsy & big. Cycle time reduction in tightening boiler structure bolts

7 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 7 Evaluation of alternatives 2. Hydraulic torque wrench  Benefits Available with leading hand tool manufacturers Widely used in manufacturing plants  Drawbacks for us Need sophisticated hydraulic equipment (difficult to maintain) Require very good quality pressure hoses to feed optimum liquid pressure to the wrench limiting factors Practically impossible to provide such facilities at sites Cycle time reduction in tightening boiler structure bolts

8 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 8 Evaluation of alternatives 3. Electrically operated torque wrench  Benefits Such wrenches are popular in assembly lines especially where job sizes are bigger & operator has to move around the job Available with leading hand tool manufacturers Electrical cables are much smaller, lighter & easily maneuverable Operate at 1 phase ac supply abundantly available at all areas of sites Cycle time reduction in tightening boiler structure bolts

9 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 9 Electrically operated torque wrench (contd..) Results of Field Trial  M/s Tristar Industrial Tools Pvt limited was a source located for making a demo at Khaperkheda  Trial was successfully done on 10 th April 2009 at a height of about 10 meters on Column number 19.  Time taken to fully tighten bolted joint by ETW was about 15 seconds as against 3 to 4 minutes by a handle type Trip Torque Wrench  Substantial saving in operation time for the activity  Saving in manual effort by Operator  Positive assurance of Quality of bolted joint. Cycle time reduction in tightening boiler structure bolts

10 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 10 Electric wrench for tightening boiler structure bolts Technische Daten DEA – Technical data DEA PLARAD – GERMANY Make Technische Daten DEA – Technical data DEA Our selection Type DEA 12 TLX Torque 200 – 1220 NM Weight 6,8 kg

11 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 11 Electric wrench tightening of boiler structure bolts

12 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 12 Electric wrench tightening of boiler structure bolts

13 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 13 Expected Benefits Tangible  Saving in Time - On average saving of about 3 minutes per bolt  Saving in manpower cost No need for Quality representative to ensure desired objective of proper tightness Additional helper to hold spanner and a trip torque wrench, not required. Intangible  Safety of Operating Personnel (Operators & others assisting him) from any Accidental fall due to Slipping  Slipping / Falling of the job from temporary scaffolding  Better safety of personnel on ground from falling of long torque wrench etc. Cycle time reduction in tightening boiler structure bolts

14 Power Sector Western Region Measurement of Face Run- out of IP & LP Rotors by improvised technique at site

15 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 15 Measurement of Face Run- out of IP & LP Rotors Normal Practice  Normal practice of measurement of face run-outs of IP & LP Turbine Rotors is To place them on saddle supports and rotate them (There is only an arc of contact between the saddle and the rotor). A pin is made and inserted in one of the coupling holes. A wire rope is wound around the rotor with the pin at one end and the crane hook of the EOT at the other. Lifting action of the crane hook causes rotation of the rotor. To aid in rotation of the rotor, copper sheets are placed in between the saddle and the rotor and, grease is smeared to reduce friction during rotation. Contd …

16 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 16 Measurement of Face Run- out of IP & LP Rotors Normal Practice (Contd..) The normal method has few problems associated with it 1.It is not possible to restrict axial movement of the rotor in order to avoid overshooting the range of the dial gauge. 2.Area of contact being very small, it requires extreme care and control while operating the EOT, lest it should cause an irreparable accident and lead to loss to both men and material. 3.It has often been noticed that there is quite an error between the measurement made at shop and those made at site leading to avoidable loss of time in correspondence, summoning experts from MUs, etc. 4.It gives the feeling of using a very primitive and un-reliable method of measurement. 5.Overall, it is never like measuring the run-outs by anchoring the rotor on a lathe to take the measurements and that’s exactly the cause of the error.

17 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 17 Measurement of Face Run- out of IP & LP Rotors Suggested New Method A simple device is made at site using the following material Shaft of 40mm Ø x 1000mm long1 no. Ball Bearings with Plummer block for above shaft 2 nos. Supports to anchor the Plummer blocks2 nos. Cross arm 1 no. Dial Gauges for mounting to X-arm 2 nos.

18 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 18 Measurement of Face Run- out of IP & LP Rotors Brg with Plummer Block Cross Arm Shaft Support provided by Unit External Support for anchoring the Plummer Block Dial Pointers Dia 40 Shaft Fixture developed and used

19 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 19 Measurement of Face Run- out of IP & LP Rotors Advantages  User friendly and costs only Rs.5000/- to make.  Does not require too much of a precision in machining the shaft.  Does away with repeated rotation of the rotor for every reading.  Reduces the risk of the rotor toppling during rotation by EOT crane.  Compares well with the values attained at works on a lathe.

20 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay This was the 1 st time the Generator Stator has been lifted by Strand Jack Method in PS-WR. Also, this is the 1 st for 250MW Stators in the whole of BHEL. Picture shows Stator lifted off the Blocks.

21 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay….Contd  Stator lifting in progress

22 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay….Contd  Stator lifted and being moved inside the A-Row of TG Building

23 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay….Contd  Stator lifted above the bottom of TG Deck and ready to be moved inside for placement.

24 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay….Contd  Picture shows the Strand Jack Hydraulic Control System

25 Stator lifting by Strand Jack Method at 1x250MW Unit#8 TATA Trombay….Contd  Picture shows stator in position  The entire operation was completed in 4 hrs from the start.

26 Power Sector Western Region PORTABLE INDUCTION HEATING MACHINE

27 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 27 INDUCTION HEATING MACHINE Conventionally, we at BHEL Power Sector Sites have been using the Induction Heating Machines of EDN Bangalore make. There are certain disadvantages of using this equipment listed below: 1. Too bulky and comes in two parts – one the Induction Heating Equipment proper and the other, the operator’s panel. Weighs a few tonnes. 2. Due to its bulk, moving the machine to different areas of work is an arduous task. Each shift of the machine is a 1 ½ days activity. 3. Often, it has been seen that when the machine is moved from one location to the other is has not been in use for a few months, the next re- start is faced with quite a few problems. The reason is not known. 4. Getting spares on time for the equipment is a big issue. This results in machines with minor repairs and requiring spares quarantined. 5. Overall the machine is not user-friendly 6. Costs around Rs. 75 Lakhs per machine

28 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 28 Induction Heating Machine -….Contd

29 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 29 Induction Heating Machine -….Contd  Alternatively, there are machines available in the market and being used by our competitors that is a vast improvement on the EDN Make machine and has the following advantages: 1. Very small and easily portable, thus rendering easy movement of the machines to various locations without loss of vital erection cycle time. Requires only a 2-3 hrs for shifting and re-connecting. The entire machine is as compact as welding transformer and is single modular. Weighs approx. 105Kgs. 2. The connections are very simple and does not need expertise. 3. Though imported, has a presence in the Indian market for the last 3 years and has been used to weld pipes of 94mm thick at Sipat. The machine can be used to thicknesses in excess of 100mm pipes as well. The size of MS Pipe for the proposed 660MW Unit with Full Flow is Φ660 x 102mm. 4. Costs only Rs.30 Lakhs. For every one machine of EDN Make, one can two of this kind.

30 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 30 Induction Heating Machine -….Contd

31 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 31 Induction Heating Machine -….Contd 660 MW800 MW SystemMaterialSizeMaterialSize MS - Half Flow P91OD 508 x 80P91ID 370 x 66 MS – Full Flow P91OD 660 x 102P91ID 480 x 90 HP Bypass – U/S P91OD x 52P91OD x 54 HRH – Half Flow P91OD 711 x 40P91OD 813 x 49 HRH – Full Flow P91OD 864x48P91OD 1016 x 58 LP Bypass – U/S & D/S P91OD 711 x 40 / OD 1219 x10 (SA691 2 ¼ Cr) P91OD 864 x 50 / OD 965 x 35

32 Power Sector Western Region Induction Heating for Opening & Tightening Casing fasteners of Steam Turbine

33 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 33 Induction Heating for opening & tightening Casing of Steam Turbine Introduction  Casing of steam turbines are tightened together by using threaded fasteners of M48 to M140 size.  These fasteners referred commonly as studs and cap nuts have to be tightened firmly to withstand the high internal pressure and temperature.  During the tightening process, specified value of elongation has to be achieved so that during working at high temperature, the nuts will not slacken.  A recommended practice for tightening these fasteners is heat tightening.

34 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 34 Induction Heating for opening & tightening Casing of Steam Turbine Commonly used devices for heating the fasteners  Electric heaters - which include heater elements, cables, power source /transformer of high capacity etc.  Gas heaters. This is relatively simpler method which uses the specially fabricated bolt heating devices - Gas Torches with special nozzles, and oxy-acetylene cylinders, compressed air supply etc. Main disadvantages of the above two methods  Long time taken for the operation  Due to the slower rate of heating, effectiveness of these methods is less and some other problems such as seizure of the threads also occur quite frequently.  Apart from this, the arrangements required are also complex and time wasted in maintenance / repairs of the equipment in case of defects is quite considerable.

35 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 35 Induction Heating for opening & tightening Casing of Steam Turbine Induction heating method for threaded fasteners  Induction heating method is being used in other site applications such as preheating of joints for special welding of alloy steel pipe lines in thermal power stations.  This method is very quick and effective means for heating.  By using some modified gadgets, it was found suitable for loosening and tightening of the big size threaded fasteners of steam turbines, valves etc.  SAS Nagpur decided to use the induction heating method for loosening and tightening of threaded fasteners.  This method has resulted in saving valuable time for dismantling and assembly of steam turbines during overhauls. The method is simple and highly effective.  With the use of induction heating method, the problem of seizure of threads necessitating cutting and gouging of the nuts and studs, in LMW design, has been minimized.

36 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 36 Induction Heating for opening & tightening Casing of Steam Turbine Comparison of time required for bolt opening 210 MW /500 MW KWUElectric/ Gas HeatingInduction Heating HP inner casing6 hrs3 hrs IP Outer casing10 hrs7 hrs IP inner casing14 hrs8 hrs  Time saved for overhauling is 3 days.  For a 210 MW set this translates into a gain of 5.04 million units perday i.e approx. Rs. 2 crore per day  For 500 mw set, 12 million units per day i.e.approx. Rs.4.8 crore perday

37 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 37 LASER ALIGNMENT KIT OBJECTIVE To carry out various alignment works in Turbine erection  With high precision.  At a reduced cycle time. WORKS CARRIED OUT  Catenary of pedestals  Centering of bores of Diaphragms, Pedestals, Shaft Seals etc.  Alignment of Rotors. CATENARY OF PEDESTALS  Accuracy of 10 Microns achievable.  Source equipments to be placed at extreme pedestals.  Mobile equipment placed in intermediate pedestals.  Laser is passed thro mobile equipment and adjustments carried out as per requirement.

38 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 38 LASER ALIGNMENT KIT Centering of Bores of diaphragms,pedestals,shaft seals etc  Source Laser device fixed in one extreme end pedestal  Receiver end device fixed in other extreme pedestal.  Special fixtures used for centering of intermediate pedestals.  Online adjustment possible. Alignment of Rotors  Can cater to Coupling Dia from 100 mm to 1200 mm.  Alignment Device fixed on couplings to be aligned  Total misalignment is indicated by just 60 degree rotation of Rotors.  Misalignment values as well as correction required indicated in display. Salient Advantages  Saving in Cycle time.  Accuracy of Measurement.  Indication of correction factors.

39 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 39 LASER ALIGNMENT KIT CONCLUSION  The Laser Alignment kit is a useful equipment that is State of the Art in Technology and can be used very effectively in Turbine activities at high precision and reduced cycle time, as has been proved in Kudankulam site. Hence extensive use of this equipment has to be practiced.

40 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 40 ORBITAL WELDING  Purpose – To provide leak proof joint between Tube to tube sheet in Condenser in addition to Forced expansion  Process – GTAW without filler wire addition  SIGNIFICANT ASPECTS  Material-Titanium  Large Qty of welding  Welding in position & at site  Material supply by Russians  TITANIUM TUBES  Grade : ASTM B 338 Gr2  Tube Sheet : mm thick  Material : ASTM A516Gr 70 + ASTM B 265 Gr 1 CLAD

41 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 41 ORBITAL WELDING  Why Titanium is used?  Provides excellent resistance to general and localized attack under most oxidizing, neutral and inhibited reducing conditions in aqueous environments.  Corrosion Resistance due to stable, protective strongly adherent oxide film which forms instantly when a fresh surface is exposed to air moisture.  This film is transparent and not deducted by visual means.  Titanium resist corrosion by sea water to temperature as high as C.  Even exposed to sea water for many years at a depth of over a mile shows no measurable corrosion.  Provides over 25 years of trouble free sea water service for chemical refinery de-salination and nuclear industries

42 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 42 ORBITAL WELDING  Has the ability to resist erosion by high velocity sea water  The presence of abrasive particles such as sand has only a small effect on the corrosion resistance of Titanium  Production began in the late 1950s  Most widely used titanium is commercial pure (99.5 % Ti)  Manufacturing Process  Ingot →slab → Hot strip → cold strip → Slitting → Forming → TIG Welding → Stress relieving → Eddy Current & Ultrasonic testing

43 Tensile, flare, flattening & reverse flattening Visual Inspection Cleanliness, ID, OD, Surface condition, end condition and marking. Tube to tube sheet joining Contact Rolling (0 to 5 % wall thinning for a length of 10 mm) Orbital Welding – For highly reliable leak tightness Forced Rolling (8 to 10 % wall thinning for a length of 25mm) Physical Testing ORBITAL WELDING

44 PROCESS FLOW CHART Front / Rear end tube sheet cleaning – wire brush mounted in portable drilling machine followed by acetone Visual inspection Titanium tube insertion Initial cleaning before contact rolling Initial contact rolling up to 10mm Sh 1 of 3

45 End facing of tube & tube sheet up to 0.05 mm Welding Visual inspection Rectification of repair work Final expansion 8 to 10 % by lubricating SAE 40 oil Excess length trimming in the rear side PROCESS FLOW CHART CONTD… Sh 2 of 3

46 Tube tightness test by MAUS Gun G-150 Dye Penetrant testing Final cleaning by acetone PROCESS FLOW CHART CONTD… Sh 3 of 3

47 TUBE SPECIFICATION

48 TUBE INSERTION AT KODAMKULAM

49 FRONIUS MODEL - FPA 2000 (AUSTRIAN MAKE) PROGRAMABLE ORBITAL WELDING MACHINES

50 AFTER TUBE INSERTION

51 TUBE SHEET PROTECTION

52 Welding parameters for FRONIUS MODEL - FPA 2000 Process : GTAW (Automatic ) No of weld passes 1 Argon Gas flow rate 4 to 6 ltr /min Pre Gas time T10 30 Sec Post Gas time T11 30 Sec Pre Fusion current I21 90A Pre fusion current time T21 0.1Sec Pulse current I22 90A Time of pulse current T22 100msec

53 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 53 USE OF HYDRAULIC OPERATED TORQUE CONTROLLED BOLT TIGHTNING KIT OBJECTIVE  To adopt a safe ‘State of the Art’ methodology in bolt stretching of coupling bolts of TG Couplings. GENERAL COUPLINNGS IN TG HP Tubine to IP Turbine IP Turbine to LP Turbine LP Turbine to Generator Shaft REQUIREMENT The coupling bolts which are like pins, having a clearance of 0.03mm diametrically, have to be stretched up to 0.55 mm,depending on the bolt dimensions to ensure uniform tightening.

54 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 54 USE OF HYDRAULIC OPERATED TORQUE CONTROLLED BOLT TIGHTNING KIT Prevalent practice Nut of the Coupling bolt is tightened by a box spanner Leverage applied on end of the spanner by EOT crane through slings. Differential expansion monitored by Dial Gauge positioned at bolt ends. Sources of Error Dial gauge at the nut end has to be fitted with a long extension rod,which may lead to error in reading. Disturbances in the nut also can lead to erratic readings. Safety element The whole stretching operation dependent on skill of the Fitter and EOT Crane operator Fine movements in EOT Crane not possible Danger of slipping/shearing always present.

55 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 55 USE OF HYDRAULIC OPERATED TORQUE CONTROLLED BOLT TIGHTNING KIT RECOMMENDATION Hydraulically operated Torque controlled Bolt tightening kit can be used. Manufacturing Unit to specify Torque tightening values of individual couplings. ADVANTAGES No error in reading. Uniformity in bolt stretching Safe for the working personnel Safe for the equipment

56 Power Sector Western Region IMPROVED PROCESSES

57 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 57 ALL-VOLATILE & OXYGENATED TREATMENT ` AVT : The basic idea of AVT is to minimize corrosion & erosion corrosion in the low temperature region by using deaerated high purity water with elevated PH. The actual PH range depend on cycle metallurgy In absence of Oxygen, the primary reaction of iron dissolution is inhibited by increasing PH. The solubility of ferrous hydrazine rises with increase in temperature and then decreases with steep drop to the solubility of magnetite between 200 – C. This results in undesirable magnetite deposit in this temperature range.

58 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 58 ALL-VOLATILE & OXYGENATED TREATMENT ` To maintain the solubility of ferrous hydroxide in feed water below or equal to that of magnetite at C and to exclude the possibility of over saturation, a minimum PH of 9.6 should be maintained. A PH of 10 would be even better. Hydrazine acts both as a O 2 scavenger & corrosion inhibitor by formation of ferrous oxide hydrate. OXYGENATED TREATMENT : This process uses oxygenated high purity water to minimize corrosion & erosion corrosion in the feed water train. Oxygen, Hydrazine peroxide, air are used as oxidants

59 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 59 ALL-VOLATILE & OXYGENATED TREATMENT ` Oxygen level should be ppb for drum units and ppb for Once Through Units. Ph level shall be at Drum units and for Once Through Units In oxygenated system, p rotective layer consists of Magnetite(FE 3 O 4 ) and Hematite(FE 2 O 3 ) layers For temperature ranges upto C the addition of oxygen allows the formation of oxide protective layer which have a very low corrosion product release rate in the following water

60 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 60 ALL-VOLATILE & OXYGENATED TREATMENT AL L VOLATILE TREATMENT (AVT) Ferrous or mixed feedwater train Cation conductivity μS/cm pH 8.8 – 9.6 (Dependent on feedwater metallurgy) Fe 10ppb N2H4 ( >3x02) O2 <5ppb NH3 ( ppm) Fe 30 ppb ) O 2 ( >30 ppb ) NH 3 ( ppb ) OXYGENATED TREATMENT (OT)  All ferrous feedwater train  Cation conductivity < μS /cm  pH 8.0 – 8.5 HP Heaters BoilerBFPDA LP Heaters CPCEP Condenser HP Heaters BFP

61 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 61 LP BYPASS SYSTEM  LP BYPASS SYSTEM MODIFICATION CARRIED OUT IN OLD LPBP SYSTEM  In case of Turbine trip, direct command will be issued to LP Bypass valves for opening upto 45% for 3 secs.  It is expected that within this 3 secs., the spray valves will open and the spray water pressure will be achieved.  However, if the spray water pressure has not reached a value of 5 kg/cm 2 within 3.5 secs., or the condenser wall temperature has become more than 90 0 C, the LP Bypass trip command will be issued

62 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 62 LP BYPASS SYSTEM  The sensing of pressure is done by installation of additional pressure transmitters at the downstream of spray water valves  The modification was implemented first in Vindhyachal U#10 and two occasions since the modification, the turbine has tripped and LP Bypass valves opened within 5 secs thereby saving the boiler trip  LBPB SYSTEM FOR NEW 250 MW SETS To address this issue, now BHEL, Hwr has gone for a new High Pressure LP Bypass system which has much better response time. Such system have been supplied at 1 x 250 MW Parli, 1 x 250 MW Paras, 4 x 250 MW JPL and 2 x 250 MW Bhilai sites.

63 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 63 LP BYPASS SYSTEM The logic provided for the operation of the LB Bypass valves are similar to that of the older low pressure LPBP valves. However, the following are the new features of High Pressure LPBP valves  The LPBP valves on sensing increase HRH Pressure, automatically opens without looking for adequate water pressure  For the water injection spray control valves, two curves have been implemented, one for control and the other for protection based on down stream pressure of LPBP valves.

64 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 64 LP BYPASS SYSTEM  If the actual water injection flow is less than flow corresponding the protection flow, then the LPBP valves closes on water injection flow protection.  The following problems have been noticed in the new system As per the water injection curve, a continuous water flow is required to the system which is unnecessary and wasteful. The spray water flow element and flow transmitter is showing 0 reading upto 50% of spray control valve opening. The problem has been taken up with BHEL, Haridwar

65 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 65 LP BYPASS SYSTEM Conclusions :  The new High Pressure system is working satisfactorily and therefore, the boiler tripping due to reheater protection in the new system has been avoided in the recently commissioned units.  By implementing the modification in the old units as done at NTPC Vindhyachal U#9, 10, the problem of the old units can also be resolved.

66 Power Sector Western Region BEST PRACTICES

67 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 67 CARD BOARD BLASTING OF LUB OIL AND CONTROL OIL LINES OF STEAM TURBINES GENERAL PRACTICE  Only mechanical cleaning is done before start of oil flushing for lub oil and control oil system of steam turbines. BEST PRACTICE  Exhaustive card board blasting along with mechanical cleaning is carried out for all the control and lub oil system before start of oil flushing.  This practice is being followed in almost all the sites now. ADVANTAGES  Effective cleaning and time reduction. Best Practices, TSX PSWR

68 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 68 USE OF PORTABLE CENTRIFUGE DURING LUB OIL FLUSHING OF ROTARY MACHINES GENERAL PRACTICE  Generally oil flushing were carried out at ambient temperature without any centrifuging arrangement for rotary machines such as BFP, ID Fans, FD Fans and Mills. BEST PRACTICE  Oil flushing is carried out with portable oil centrifuge having in- built heating arrangement. ADVANTAGES  Effective cleaning and time cycle reduction. Best Practices, TSX PSWR

69 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 69 CHEMICAL CLEANING OF PRE BOILER SYSTEM WITH CEP GENERAL PRACTICE  Carried out by using temporary pumps, tanks and piping along with boiler acid cleaning setup BEST PRACTICE  Existing CEP and Hotwell are used for the purpose of circulation in the entire system ADVANTAGE  Effective cleaning of the entire system with minimum number of temporary loops  Cost and time cycle reduction Best Practices, TSX PSWR

70 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 70 USE OF DEAERATOR AS MIXING TANK FOR PRE- BOILER FLUSHING GENERAL PRACTICE  Mixing tanks and associated pipings are arranged for carrying out the pre boiler flushing activities. BEST PRACTICE  For industrial sets, Deaerator itself is used as mixing tank for carrying out chemical cleaning of pre-Boiler system.  This results in cost and time cycle reduction. Best Practices, TSX PSWR

71 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 71 CHEMICAL CLEANING OF BOILER (WW, SH) AND MS LINES IN INDUSTRIAL PROJECTS GENERAL PRACTICE  Stages are : Alkali boilout, Acid cleaning and passivation BEST PRACTICE  Alkali flushing, Citric acid cleaning, passivation of the entire system ADVANTAGE  Chemical cleaning activities can be completed even before Boiler light up  Since both SH and MS lines are acid cleaned & steam blowing cycle is considerably reduced  Cost and time cycle reduction Best Practices, TSX PSWR

72 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 72 CHEMICAL CLEANING OF HSD AND NAPHTHA LINES IN CCPP GENERAL PRACTICE  Cleaned by card board blasting BEST PRACTICE  Citric acid cleaning with passivation ADVANTAGE  Where the length of HSD and Naphtha lines is more than 500 meters cardboard blasting shall not be very effective. Hence, citric acid cleaning is a most effective way of ensuring cleanliness of the entire piping  Time cycle reduction and trouble free operation Best Practices, TSX PSWR

73 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 73 USE OF THERMIC FLUID HEATER FOR COMMISSIONING ACTIVITIES IN GREEN FIELD PROJECTS GENERAL PRACTICE  Auxiliary boiler is used for generation of steam for pre- commissioning activities like flushing of Boiler Feed Line, Condensate Lines, Drip Lines etc. BEST PRACTICE  Thermic fluid heater is used in green field projects in place of auxiliary boiler for carrying out chemical cleaning activities.  This results in cost and time saving. Best Practices, TSX PSWR

74 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 74 ACID CLEANING WITH EDTA GENERAL PRACTICE  Generally HCL is used for acid cleaning of main boiler. BEST PRACTICE  HCL is replaced by EDTA for all green field projects especially, where auxiliary steam is not available.  This is safe, environment friendly and reduces time cycle. Best Practices, TSX PSWR

75 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 75 PROVISION OF ADDITIONAL INTERSTAGE VALVES FOR STEAM BLOWING GENERAL PRACTICE  Interstage valves are not used during steam blowing operations resulting in three to four days shut down for start of subsequent steam blowing operations. BEST PRACTICE  Additional temporary valves are used at Main Steam HP Bypass lines, CRH Lines during steam blowing operations.  This has resulted in cycle time reduction. Best Practices, TSX PSWR

76 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 76 CONTINUOUS STEAM BLOWING IN CCPP GENERAL PRACTICE  Puffing method is used due to limitation of fuel firing system BEST PRACTICE  Continuous blowing method (30 minutes) is used in stages ADVANTAGE  Effective cleaning and time cycle reduction Best Practices, TSX PSWR

77 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 77 HIGHER STEAM BLOWING PARAMETERS GENERAL PRACTICE  Steam blowing is carried out at 40 Kg / sq cm and 300 – 350 deg C BEST PRACTICE  Steam blowing carried out at 50 Kg / sqcm and 370 – 400 deg C ADVANTAGE  Effective cleaning due to higher disturbance factor at elevated parameters  Time cycle reduction Best Practices, TSX PSWR

78 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 78 USE OF FRESH LUB OIL BOTH FOR FLUSHING AND REUSE IN ALL INDUSTRIAL SETS GENERAL PRACTICE  Flushing oil is used for oil flushing operation, fresh oil is used for normal operation BEST PRACTICE  After cleaning of entire lub oil system by cardboard blasting fresh oil is used both for flushing and normal use ADVANTAGE  Cost and time cycle reduction Best Practices, TSX PSWR

79 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 79 AIR LEAK TEST OF LUB OIL, CONTROL OIL, AND CONTROL FLUID SYSTEM GENERAL PRACTICE  No separate test conducted before start of flushing resulting in leakage of oil / fluids BEST PRACTICE  Entire system is pressure tested with compressed air at 5 to 6 Kg/sqcm before start of flushing operation ADVANTAGE  Leakage of oil and control fluid is minimised  Cost and time cycle reduction Best Practices, TSX PSWR

80 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 80 GENERATOR SEAL OIL FLUSHING GENERAL PRACTICE  Seal oil flushing is done for the site erected pipes upto the inlet nozzle in the end shield BEST PRACTICE  Pre-fabricated pipes from the end shield upto seal ring inlet are also included in the final stage of flushing. ADVANTAGE  Avoids damage to Generator seal from the entrapped foreign material. Best Practices, TSX PSWR

81 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 81 HYDRAULIC TEST OF LUB OIL, CONTROL OIL AND SEAL OIL LINES GENERAL PRACTICE  Jacking oil pumps were used for carrying out hydraulic test of lub oil, control oil and seal oil line after flushing. BEST PRACTICE  AC seal oil pimp is used for the purpose of hydraulic test of the above system. ADVANTAGE  Avoids damage to Jacking oil pumps. Best Practices, TSX PSWR

82 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 82 CONDENSER MASS FLUSHING GENERAL PRACTICE  Cleaning of condenser is normally carried out during steam dumping operation BEST PRACTICE  Condenser tubes are thoroughly flushed through high pressure jets (fire fighting water) before commissioning of CEP ADVANTAGE  Duration of steam dumping operation reduced  Cost and time cycle reduction Best Practices, TSX PSWR

83 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 83 CLEANING OF VACUUM PUMP SUCTION LINES GENERAL PRACTICE  No structured cleaning is envisaged except draining the system through drain valves (NB50) during initial commissioning of vacuum pumps BEST PRACTICE  Vacuum pumps suction lines are throughly cleaned through cardboard blasting before commissioning of vacuum pumps ADVANTAGE  Smooth trouble free operation  Damage of vacuum pumps due to entry of foreign material is avoided Best Practices, TSX PSWR

84 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 84 OLTC COMMISSIONING GENERAL PRACTICE  OLTC is commissioned normally after attaining continuous operation of unit, i.e., CW system has been put into service for prolonged period BEST PRACTICE  OLTC is commissioned either  Immediately after running of CW pump or  Before conductance of PG test after thorough cleaning of condenser tubes ADVANTAGE  Collection efficiency of balls increase  Trouble free condenser operation Best Practices, TSX PSWR

85 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 85 SELF CONTAINED BEARING COOLING ARRANGEMENT AT EPC PROJECT GENERAL PRACTICE  Lub oil coolers for ID, FD and PA Fans are kept charged through the bearing cooling water system BEST PRACTICE  In EPC project where due to certain circumstances there is a delay in commissioning of Cooling Water system a separate self contained cooling arrangement (Sintex tank, pumps and suitable hoses) to facilitate initial commissioning ADVANTAGE  Trial operation of all major boiler auxiliaries can be completed by this method leading to time cycle reduction Best Practices, TSX PSWR

86 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 86 PRE ERECTION CHECKING OF BUS-DUCTS General Practice  Bus-ducts are cleaned and erected  Commissioning jobs taken up later Best Practice  While at ground, check tightness of all electrical connections of heaters, thermostats etc  Check heaters healthiness and adjust thermostat tripping points easily now  Check drain pad holes before lifting so that any corrections, if required can now be done easily  Trial assembly of Bus-duct structure on ground before erection  Avoids difficulty in commissioning / troubleshooting Best Practices, TSX PSWR

87 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 87 TURBINE X-CRITERIA General Practice  In X1 criteria for turbine rolling, main steam inlet temperature to turbine has been used for criteria calculation. During any boiler trip and restart, X1 criteria gets fulfilled even though boiler outlet temperature is less. This leads to cold steam entering the turbine...Best Practice  Additional criteria X11 introduced using Temperature before HP bypass. Best Practices, TSX PSWR

88 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 88 ADDITIONAL TRIPPING DURING ATT General Practice  Tripping criteria during conductance of ATT does not include many vital trip inputs..Best Practice  Conditions like MFT, Turbine Bearing temperature VH, axial shift VH, vacuum low, cold gas temp trip, seal oil temp trip etc are added Best Practices, TSX PSWR

89 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 89 COMMISSIONING OF ATRS, ATT & AUTOSYNCHRONIZER General Practice  Normally, ATRS, ATT and Auto-synchroniser are getting commissioned as pending points and not as a part of normal plant commissioning.  So after the ‘pending point’ is cleared, customer is normally not using the system. Best Practice  We are putting efforts for commissioning these system in the first rolling synchronisation itself.  Recently at Bhilai and Tata Trombay, ATRS and Auto-synchroniser have been commissioned during first few start-ups.  At Tata Trombay, ATT is also commissioned. Best Practices, TSX PSWR

90 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 90 DC EOP AND SOP LATCH RELAY General Practice  Lub Oil pressure low switch starts DC EOP through max system SLC latch relay contract... Best Practice  SLC latch relay contract in DC EOP and SOP cabinet looped so that lub oil pressure low switch contact starts DC EOP and SOP directly, bypassing MAX system SLC ON.  This safeguards machine in the event of AC as well as failure of max system Best Practices, TSX PSWR

91 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 91 AUTOSYNCHRONIZATION General Practice  As per circuit configuration, auto synchronizer after fulfilling its set condition directly closes the Generator circuit breaker...Best Practice  Additional contact of check synchronization relay wired up in auto synchronization circuit. Here autosynchroniser setting are coordinated with setting of check synchronizing relay so that autosynchroniser and check synchronization relay operates at the same time.  This helps in safeguarding the machine during malfunctioning of autosynchronizer. Best Practices, TSX PSWR

92 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 92 AUTOSYNCHRONIZER TESTING General Practice  As per normal practice, autosynchronizer is tested and its output command is verified within the panel terminals.. Best Practice  Autosynchronizer is tested in cold condition with supply of PT voltages through injection kit and actual Generator breaker closing (ensuring that isolators are open)  This helps in optimization of autosynchronizer setting more correctly and also total circuit gets checked. Best Practices, TSX PSWR

93 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 93 USE OF MULTIPLE FILTRATION MACHINES FOR TRANSFORMER DRYOUT General Practice  One Oil filtering machine (about 6 KL capacity) engaged for dryout Best Practice  More than one such machine put in parallel operation to optimally utilise transformer drain header flow capacity Advantage  Cycle time reduced around 50% Best Practices, TSX PSWR

94 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 94 TURBINE BEARING METAL TEMPERATURE CHECKING General Practice  As per normal practice, cabling from bearing metal temperature JB to control room/Cold Junction Compensation(CJC) JB are checked after installation of thermocouple in bearings...Best Practice  Before installation of thermocouples in bearing, signal upto DCS checked by heating the thermocouple tag wise.  This ensures correctness of connection, readings and also ambiguity of polarity change is avoided. Best Practices, TSX PSWR

95 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 95 DAVR DUMMY LOAD TESTING General Practice  As per normal practice, the AVR/DAVR dummy load testing is carried out at site with the help of 500W lamp or any available resistive load...Best Practice  Dummy load testing is carried out with same type of resistive load which is identical in ratio to that of factory testing. With this type of testing, exact and identical readings with factory can be ensured.  Customer as well as commissioning engineer gets better confidence on DAVR working. Best Practices, TSX PSWR

96 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 96 PAINTING OF TRANSFORMERS AND BUS-DUCTS General Practice  Painting works for busducts and transformers are attempted at very late stages  Becomes difficult because of shutdown requirement and thus opportunity may not be there Best Practice  At least Station transformer and its busducts may be painted immediately after erection completion (before first charging). This transformer hardly goes into shutdown later  Better to paint the other transformers and busducts as well as soon as possible before charging  However, customer opinion / permission may be required since they may insist on painting only after all works are completed Best Practices, TSX PSWR

97 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 97 SEQUENCE STARTUP OF HT DRIVES General Practice  All HT drives are generally started individually during first commissioning of the drives  This lead to a pending point as we do not get suitable opportunity to commission the HT drives in sequence mode Best Practice  All the HT drives to be started in sequence during first startup of the any HT drive Best Practices, TSX PSWR

98 Power Sector Western Region Process improvements Adopted During Overhaul by PSWR-SAS Nagpur

99 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 99 Introduction Implementation of Best Practices during Overhauling of T.G. has resulted into the following -  Overhauling cost reduction.  Reduce overhauling periods.  Improvement in quality.  Introduce latest technologies.  Improve customer satisfaction

100 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 100 Implementation of Best practices  Use of latest technology like induction heating for dismantling and assembly of turbine.  Unit de-synchronization at 480 ºC of HP shaft temp by decreasing the load before shut down..  Turbine oil pump stop at 125ºC (HPS temp).  Barring gear stop at 125ºC (HPS temp).  To initiate overhauling activities as soon as machine comes to barring gear.  Decoupling of Generator rotor from turbine rotor and put back turbine rotor in barring.  Start dismantling of generator and O/H activities thereafter.

101 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 101 Review by Site and follow-up from HQ  Site reviews all activities minutely  Time taking processes, idle times between activities, delay in arranging spares and mobilization of experts from units etc are identified well in advance.  HQ also involves in reviewing processes and all important issues and HQ inputs are duly incorporated on activity planning at site.  Reduction in overhauling duration to the target schedule is attributed to meticulously planning and follow-up of critical activities, which is accomplished in a shortest duration.

102 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 102 Strategic Planning  List out the History of past problems  Pre-overhaul survey record.  Analyze Present running behavior.  Input from MOU’s and utilities.  Timely arrange experts service from MOU’s  Milestone based review.  Mobilization of resources 3 days before start of Overhaul.  Scheduling of sequential & parallel activities  Identification of idle time & to avoid them by detailed planning in advance  All the anticipated spares required for completion of the overhauling work arranged at T.G. Floor before start of the work.

103 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 103 Generator work starts within 36 hrs of De-synchronization  0000 hrs : De-synchronization (HP shaft temp at 480 Deg.C)  17.5 hrs : Barring gear stop (HP shaft temp at 400 Deg C)  17.5 hrs. to 20.5 hrs: AOP stop Lub oil to brg. 5,6,7 blanked & brg. 4 minimized LP-Gen coupling decoupling Hand barring will continue during this period  20.5 hrs : B/G re-started  With this practice Generator rotor thread out work starts within 36 hrs of de-synchronization.

104 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 104 Procedure for decoupling of LP-Generator in hot conditions  Turbine is on Turning Gear. JOP in service, AOP in service.  Loosening of pedestal cover bolts, removal of Vibration probes.  Close turning gear valve to reduce the speed. Simultaneously loosen and remove pedestal cover bolts.  When Turbine speed becomes zero. Stop AOP while JOP is continuously kept in service. Continue Hand Barring.  Remove pedestal 4 cover. Close Lubricating oil throttle valve to the minimum possible.  Simultaneously blank lub oil supply to bearing 5,6 and 7 by putting gasket in lub oil supply line. (parallel, by 3 gangs). Keep watch on bearing 1,2 and 3 metal temperature and simultaneously do hand barring.

105 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 105  Put tin sheet/polythene to cover on bearing 4. Start EOP and continue hand Barring.  Loosen LP-Generator coupling bolts and decouple LP-generator by continuing hand barring.  Shift generator rotor away from turbine Stop EOP and Adjust brg. 4 lubricating oil throttle valve to normal. Put pedestal cover back and start EOP & barring gear.  Dismantling & prepare for rotor thread out.  At the time of rotor thread out, stop turning gear again and stop EOP. Remove pedestal 4 cover.  After thread out put pedestal 4 cover back. Turbine on Barring gear with AOP in service till HP shaft temp comes to 125 deg C. Note: Jacking oil pump is throughout kept in service. Procedure for decoupling of LP-Generator in hot conditions

106 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 106 PSWR’s Best records on TG overhauls  Overhauling of IP-LP Turbine & Generator including LP Turbine blades MPI have been carried out in record lowest time of 8½ days barring to barring. (13 days Bar to Bar) on year 2007 at 250MW U#2 Dahanu TPS.  Overhauling of LP Turbine & Generator have been carried out in record lowest time of 9 days barring to barring. (15 days Bar to Bar) on year 2005 at 250MW U#2 Dahanu TPS. This was achieved as an exceptional case to avoid power problem in Mumbai.  Overhauling of HP- LP Turbine & Generator including HP rotor replacement & HP/IP coupling hole reaming, LP free standing blades MPI & NFT along with bearings 1,2 & 4 replacement have been carried out in record lowest time of 13 days baring to barring. (18 days Bar to Bar) on year 2006 at 250MW U#1 Dahanu TPS.

107 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 107  Overhauling of IP-LP Turbine & Generator including LP Turbine blades MPI & NFT have been carried out in record lowest time of 12 days barring to barring. (17 days Bar to Bar) in year 2008 at 250MW U#2 Dahanu TPS.  Unit-3 HP Module overhauled in 14 days barring to barring (19days bar to bar) in year 2006 at 200MW U-3 KSTPS NTPC Korba.  Capital Overhauling of HP-IP-LP Turbine & Generator including HP rotor replacement & HP/IP coupling hole reaming, LP free standing blades MPI & NFT have been carried out in record lowest time of 35 days barring to barring in year 2008 at 500MW U#8 NTPC VSTPS Vindhyachal. PSWR’s Best records on TG overhauls

108 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 108 Schedule comparison Sl. NoCapacity (MW) Capital Overhauling TG SET (Barring to Barring) Previous Best RecordPresent Record 1500 (All three module + Gen) 36 Days Unit-6, NTPC,KSTPS Korba on year days Unit-, NTPC, VSTPS Vindhyachal on year (HP-LP&GEN) 30 Days Unit-U-2 REL, Dahanu TPS on year days Unit-U-2 REL, Dahanu TPS on year (IP-LP&GEN) -8½ days Unit-U-2 REL, Dahanu TPS on year /210 (HP Module) 28 Days Unit-2 NTPC KSTPS on year Days Unit-3 NTPC KSTPS on year 2006

109 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 109 Conclusion  A benchmark on record minimum duration in KWU design TG set overhaul could be achieved.  It was the determination, commitment, monitoring and follow-up of associated activities that ascertained to achieve a challenging target.  Working out activities well in advance with subcontractor agencies/ partners and round the clock execution of job with new strategies helped to meet schedule deadlines.  Work can be started as soon as machine comes to Barring gear.  Cooling Down period can be saved relatively by 4 days during the Generator overhauling.

110 Power Sector Western Region IMPROVED SITE FACILITIES

111 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region /04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 111  Award of Enabling works and its construction takes considerable time, after receipt of confirm order. This delays posting of site staff and material management including posting of Construction Manager.  PSWR has decided to procure Porta Cabins with all amenities as replacement of Conventional Site office sheds.  This will be provided in all new sites like Satpura, Mauda, Chandrapur, Raigarh, Vindhyachal, Bela Ideal Energy including all forthcoming sites.  NIT has been floated and tender is likely to be finalized by end April Porta Cabins - to overcome delay in site mobilisation

112 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 112

113 23/04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region /04/2015 Exploring Heights Setting Standards Marching Towards Excellence Power Sector Western Region 113 Advantages of Porta Cabins 1.Quick mobilization 2.Quick realization of mobilization advance from customer 3.Quick demobilization 4.Flexibility in use & can be installed as per the site condition 5.Environmental friendly due to cleanness & easy maintenance 6.Provide better facility to site staff 7.Light weight (Easy in handling and transportation) 8.Aesthetic look. 9.Durable and Termite proof 10.Seismic-resistant 11.Economical in long term because of repetition 12.Thermal Insulation Porta Cabins - to overcome delay in site mobilisation

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