Description S.No. Execution of Plant Start Up Items:(Updated Additional Items Updated on 21.02.2012 Additional Items Updated on 02.04.2012 on 19.01.

2012) 1 GAS TURBINE

2 3 4 5 6 7 8 9 10 11 12 13 14 Mechanical
Local Services for air intake upgradation work Services for GT insulation work PCM Nr. 3-10-002450 Turning gear start from standstill issue( this job to be performed by Siemens during Plant Commissioning) New/Improved Air intake Filter House and accessories. GT Lube oil for top up (5 drum) GT Air Intake & Elbow Duct waterproofing 1 1 1 1 1 1

Priority
1

I&C
Redundancy in GT TXP compact unit /Procurement of TXP Compact Unit. Adjust pilot gas flow for load rejection to island mode. GT was last tripping out seconds after coming into island mode. (This commissioning issue to be resolved by Siemens) N95F failure investigation (This commissioning issue to be resolved by Siemens) Siemens training on control systems(TXP,SIMADYN,95F and PCS7) Replace MOD and reslove inability to log on to TXP Engineering Server E680(Resolution of this problem is essential until the redundancy of the compact unit is provided) TXP: Error Alarm persisting on OSM, connection b/w the engg. station and the redundant CPU failed just when on line logic transfer was attempted. Gas Turbine: one of the two GT compressor discharge thermocouples is not working. Needs to be ordered. Siemens expert for DCS,TXP and PCS7 to resolve items 49 to 51 and 53 to 57 by providing services at site. Siemens Fact Finder June 2010 -Connection of surge protection is located at the lower half of the compressor inlet. Recommended to change it to upper half with a continuous garde to the compressor(Siemens Commissioning Engineer to check and advise) System Field Programmer (PG): Original hard drive is faulty, however one image is available with which PG is operating well.This matter needs to resolved before start of commissioning activity. Purchase of GT Exhaust Thermocouples 1

1 1

15 16 17

18

19 20 21 22 23

1 1 1

Electrical
Ignition Cable and Ignition Transformer

Chemistry

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Washing Detergent for GT

1 1 O-Ring replacement of ESV at HP Steam Line

STEAM TURBINE
Mechanical

I&C
Installed CPU of Steam Turbine got defective. Spare CPU is now installed. One spare CPU to be ordered for emergency. PCS7: Engineering Station WIN CC runtime and RAID not working. Purchase of Spare Fuse Boxes for Steam Turbine panel. 1 1 1

Electrical
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GAS COMPRESSOR
Mechanical
Gas compressor # 1 & 2 servicing for ensuring 100% reliability of both gas compressor including spare part required for servicing. Gas Compressor 1& 2 Oil Replacement Level glass and isolating valves installation at Cylinder Water/Packing Water/Lube oil overhead tanks Gas pipe lines'/filter housings' internal cleaning ( to remove loose particals accumulated inside pipes due to external mechanical works for painting Non Sparking and other tools Gas Filter for Initial & Final separator 1 1 1

1 2 1 1 2 2 2

I&C
Installation of A/C unit for gas compressor PLC panel Diaphragm for inlet valve of fuel gas compressor Gas Compressor fire fighting system spares detectors are required and additional trolley type fire extinguishers to be addded. Power Supply for the PLC of Gas Compressor to be ordered.

Electrical
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Chemistry
Coolant (glycol) 1 1 1 1 2 1 1 1 1 2 1 Change hydraulic oil in SWI hydraulic valves. 1

SEA WTER INTAKE CHANNEL

Mechanical
Steel Mesh for TBS(All) endless rubber seal for TBS (PR is on hold ) Checkers' plates re-inforcement/replacement at Pump basin and painting the supporting structure Services for Cleaning of sea water Intake channels, pump basin and pipes from silt. Maintenanace & Repair works in Sea Water IntakePenstocks etc. Shock chlorination in Intake and SW header. Repairing/rehabilitation of Chlorine dosing system Reisntallation of marking buoys for Intake at Off shore Chlorine unloading pumps (maintenance/replacement)

63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82

Replacement of all the lip Seals at Bar-Screens and Travelling Band Screens

I&C
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Electrical
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Chemistry
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BOILERS
Mechanical
HRSG and Aux Boiler safety valve inspection, servicing and testing. Fabrication of guard cage around the HRSG stack at ground level for protection Oil analysis of all lube oil system Fixing of all leakages and other defects of the dosing system (Remineralized water System) Cut Samples of HRSG tubes and test/ analyse for condition Replacement of existing stubs on HRSG. Hydrostatic Testing of HRSG Renewal of certification of Main and Aux boiler Acid Cleaning for HRSG, if necessary. Gaskets for Deaerator/HP drum/LP drum and Flash Tank mon hole Replacement of HRSG tubes, if necessary. Replacement of Access Door's Collor at Transition Piece. Aluminium Cladding at some valves and pipes (where cladding is damaged) 1 1 1 1 1 1 1 1 2 1 1 1 2

83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 109 110 111 112

I&C
I/O cards for HRSG Panel( 2nos.) Replacement/repair of field instruments and servo motor for Aux. Boiler. Diaphragm for LP & HP drum control valve Purchase of Drum Instruments (pressure Tranimitters & level transmitters) Channel fabrication for mounting limit switches Purchase of Servo motor and modulating pressure transmitter Diaphragm for Attemperator Control Valve Pressure Transmitter for flue gas path Replacement of faulty thermocouples( 8 nos) Replacement of Air Filter Regulators(15 nos.) Manifolds for I&C (5 nos) 1 1 2 2 1 2 2 1 1 1 1

Electrical
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Chemistry
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FINE FILTRATION
Mechanical
Inspection/supervision of repairing work of MicroGiant's drive system and Bearings replacement by Passavent Engineer Nylon Mesh for Microgiant screen

1 1

113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139

Fixing of leaking penstocks Repair/touch up work on Coating applied at walls of the pump/MG basin's. Shock chlorination in FF Tank Fine Filtration DWT Pumps' internal inspection and servicing as per findings Rehabilitation of backwash system at MG FF Tank's roof repairing work

1 1 1 1 1 1 1 Level Transmitter Rehabilitation of Control Panel of Passavant 2 2

I&C
AUMA actuator for Fine Filtration(2nos.)

Electrical
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Chemistry
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MAIN GENERATOR
Mechanical --

I&C
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Electrical
Tan Telta Test for Main Generator 2 1

GAS INSULATED SWITCH GEAR (GIS)

Mechanical --

I&C
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Electrical
The differential protection for Defence and Creek feeders are not available due to problem in fibre optic cable on DHA and KESC end. To be attended by KESC. Further, KESC have to repair 132KV cable for Creek City feeder. Replace defective Rectifier for DC Power Supply System in GIS building. Exhaust Fans in Buildings(GIS, Chlorine Dosing) 1

140 141 142 143 144

1 2

DESALINATION PLANT
Mechanical
Repair of 200 micro filter basket for feed water Condensate Return high conductivity fixing and identification of leaks. Non Asbestos gasket sheet BA-50 for Desalination flange (1500 x 1500 x 2mm) Spare Bellows required to replace damaged ones steam Jet Ejectors complete servicing Distillate coolers' (PHE) cleaning internal inspection of Butterfly valves installed at Desalination units and servicing as per requirment Cyclone separators complete servicing Replacement of Root Valves at impulse line on process header (Different sizes) and all areas. Foreign purchase of Fapmo pump shaft & bearing housing 1 1 1 1 1 1 1 1 1

145 146 147 148 149 150 152

153 154 155 156

Plastic inserts for copper tube for End-Condenser and Preheaters Chemical unloading pumps (maintainance/replacement) Inspection and Commissioning supervision by OEM Engineer Modification of Filter housing as per Fichtner's recommendation Desalination Units Chemical Cleaning (PHE & Preheaters) as per OEM recommended procedure Feed Water Filters' (200 m) teflon bushes repairing/replacement

1 1 1 1

157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177

I&C
Arrange software back up (S7+WinCC Flexible) and attend following requirements from Operation : 1) Missing measurements for brine, conductivity,, pressure and temp. to CCR. 2)Make flow meter/converter functional for distillate. 1

Electrical
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Chemistry
Anti-Scalant Chemical 1

POTABLE WATER AND REMINERALIZATION SYSTEM

Mechanical
Fixing of all leaking penstocks in PWST. Modification work at H2SO4 line as per M/s FICHTNER recommendations 1 1

I&C Electrical
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Chemistry OTHERS
Mechanical
Risk Matrix spares, Mechanical ( Annex 3.1) Various wear Spare Parts for plant required before startup for MMS, IMS and EMS (NB: a number of purchase requisitions for spares required for corrective/preventive maintenace kept on hold since last one and a half year) 1

178 179 180 181 182 183 184

Maintenance services for product Water storage tank

Submersible pumps (maintainance/replacement) Procurement of Rupture Disk (2 Nos) Fixing of leaking penstocks in PWST Lube Oil analysis of various systems Fixing of all leakages and other defects of the dosing system (Remineralized water System) Refurbication of various Valves

2 1 1 1 1 1

185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203

I&C
Risk Matrix Spares, I & C ( Annex 3.3) Diaphragm for LP & HP by-pass valve Fire detectors with accessories to replace defective ones for BoP from MINIMAX. Motors for each type of Actuator(6 nos.) Electronic Assembly for each type of Actuator(6 nos.) Certification of Caliberation of critical Instrument Drain Points on positioners 1 2 1 2 2 2 1 1 2 2 2 1 Electrical Protection Relays Electrical Protection Relay Testing 1 1 1 1

Electrical
Risk Matrix Spares, Electrial( Annex 3.2) Plant UPS system battery discharge test Purchase of Electrical Motors(Used) Spare Cells for NiCd Battery Bank( 8 nos.) Purchase of Siemens Over Current Relays( 2 nos.)

Chemistry
Chemicals for Start Up. Purchase of Demineralized water for start up

Total: