Genting Lanco Power Monthly Maintenance Report

Genting Lanco Power (India) Private Limited
Lanco Kondapalli Power Plant

Kondapalli IDA - 521 228
Krishna District, ISO 9001 ISO 14001
Andhra Pradesh, India
Tel No.: +91 866 2872 807; 2872 808
Fax No.: +91 866 2872 806
OHSAS 18001
Monthly Maintenance Report

February 2013
8 PLANT MAINTENANCE (Phase-I)

8-1 Status of Work Requests/ Work Orders
Total number of Carried forward Work Requests is : 50
Total number of Work Requests raised in current month is : 106
Total number of Work Requests is : 144
Total number of Completed Work Requests is : 89
Total number of completed Preventive maintenance job is : 127
Sl no Description C&I Elec. Mech.

A Unscheduled Maintenance
1 No of Work Requests: Carried forward from last
10 0 13
month
2 No of Work Requests: Raised during current month 08 106 33
3 Total No. Of Work Requests 18 106 46
3.1 No of Work Requests Completed 09 106 33
3.2 No of Pending Work Requests: Need Plant Shut down. 06 0 07
3.3 No of Pending/Job in progress Work Requests 4 0 26
3.4 Pending Requests: Pending for Resources 10 0 13
B Preventive Maintenance
4.1 Raised in the current month 43 54 49
Completed during Current month 43 54 43
C Miscellaneous (Painting, repairs etc)
5.1 No of Jobs/ Work Requests: Carried forward from last
0
month
5.2 No of Jobs/ Work Requests: Raised during current
0
month
5.3 Total No. Of Work Requests 0
5.4 No of Work Requests Completed 0
5.5 No of Pending/Job in progress Work Requests 0
5.6 Pending Requests: Pending for Resources 0
Lanco Kondapalli Power Project Page 1 of 22

Genting Lanco Power (India) Private Limited Monthly Report: February 2013.
8-2 Plant Major Maintenance Schedule:
Sl Previous Executed Remarks

Equipment Planned
no
MI: Oct-2006
1 Gas Turbine#1 2nd MI: Jun-2013 HGPI: Jan-2004 & May-2010
CI: May-2010
MI: May-2007
2 Gas Turbine#2 2nd MI: Jan-2013 HGPI:July-2003& Oct-2009
CI: Oct-2009
3 Steam Turbine June-2013 Aug-2011
4 HRSG#1 Apr 2012 Apr-2011
5 HRSG#2 June-2012 June- 2011
8-3 Statutory Inspections:

 Nil.
8-4 Emergency breakdowns and Repairs:

 Nil.
8-5 Key Issues:

 Nil.
8.6 Phase: 1 Mechanical Maintenance
8.6.1 Following unscheduled Maintenance jobs completed
 HRSG#1, MOV-3022, gland leak arrested.

 CT#3 and 12, trash screens cleaned.
 GT#1 HSD F/W PUMP#A Suction I/V gland leak arrested.
 Compressor air system, Air dryer-B, NRV replaced.
 STG Lube oil cooler (modified) hydro test was done.
 Cooling tower fan assembly, CELL No-11, oil seal replaced.
 HRSG#1, IP super heater drain MOV gland leak arrested
 CW chlorine booster pump common discharge leak near CT cell#1 back side arrested.
 HRSG#1 HP TSP dosing pump # B, oil seal replaced due to leak.
 DM plant inside LBC power water line header leak arrested by welding.
 Naphtha forwarding pump#4 discharge valve gland leak arrested.
 Raw water chlorinator A&B Flow problem rectified.
 MB-A, acid injection line dechocked and water entering AMT-2 tank problem rectified.
 GT, Removed inlet air filters cleaning done.
 STG Lube oil filter -A cleaning done.
 Naphtha forwarding pump discharge filter (*gas turbine#1) housing gasket replaced and
leak arrested.
 RW Chlorinator-A (North Side) PVC line broken between chlorinators and ejector, leak
arrested.
 False start sump pump, gt#2, flow problem rectified

8.6.2 Scheduled Maintenance:
Following equipment Preventive Maintenance jobs completed.
 Cooling tower fan assembly, CELL No-1.

 CW chlorine booster pump – A.
 Condenser CW circulating pump - B (MCW-B).
 Diverter damper seal air fan - A, HRSG 1.
 Diverter damper seal air fan-A, HRSG#2.
 Auxiliary Cooling Water pump – A.
 Diverter damper seal air fan - B, HRSG 1.
 Diverter damper seal air fan-B, HRSG#2.
 Closed circuit Cooling Water pump – 2.
 De-gasser blower - A, DM Plant.
 Air scoring blower - A, for sand bed filters.
 HSD forwarding Pump - A, GT #1.
 HSD forwarding Pump - B, GT-2.
 HSD centrifuge 1.
 HSD centrifuge Booster pump – A.
 Clarified water pump – B.
 Cooling Tower make up water pump – A.
 TSP HP dosing pump - A, HRSG # 2.
 TSP IP dosing pump - A, HRSG # 2.
 Closed circuit Cooling Water pump – A.
 TSP HP dosing pump - B, HRSG # 2.
 Clarified water pump-A.
 De-gasser blower - A, DM Plant.
 Air scoring blower - A, for sand bed filters.
 Mixed bed air scoring blower-A, D M plant.
 Regeneration water pump - A, D M plant.
 Jockey Pump # 6.
 Mixed bed air scoring blower-B, D M plant.
 D M feed water pump-19.
 HSD forwarding Pump - B, GT #1.
 HSD forwarding Pump - A, GT #2.
 Oily water sump pump-A in tank farm area.
8.6.3 Condition monitoring jobs:
8.6.3.1 Following scheduled condition monitoring jobs completed
 HP / IP Boiler Feed water Pump – B

 LP Boiler Feed water Pump- A
 LP Boiler Feed water Pump- B
 HP BFP-B Lube oil pump-1
 Auxiliary Cooling Water pump – A
 Auxiliary Cooling Water pump – B
 Auxiliary Cooling Water pump – C

 Cooling tower fan assembly , CELL No-1

 Cooling tower fan assembly, CELL No-2
 Clarified water pump –A
 Clarified water pump –B
 Degasser water pump-A
 D.M. Water Transfer pump- A
 DM feed pump-18
 Service/Portable water pump-22, DM plant
 Neutralized waste disposal pump-A
 Jockey pump-6
 Jockey pump-7
 Water circulation pump – A, Fin fan, GT #1
 Water circulation pump – B, Fin fan, GT #1
 Water injection pump-2, GT#1
 GT-1 BT fan-1
 GT-1 VG fan-1
 GT-1 EF fan
 Condensate Extraction Pump – A
 Condensate Extraction Pump – B
 Condenser Vacuum pump – A
 Condenser Vacuum pump – B
 Closed circuit Cooling Water pump – 2
 Main lube oil pump – 2 (A.C.Driven)
 Gland steam condenser fan-1
 Gland steam condenser fan-2
 EHC oil pump-1
 EHC oil pump-2
 Diverter damper seal air fan –A HRSG #1
 Raw water pump-C
 Raw water intake pump-A
 Raw water intake pump-B

 Raw water intake pump-C
8.6.3.2 Following unscheduled condition monitoring jobs completed.
 Jockey pump-6 vibration on slightly higher side, trend maintained steadily.

 ACW pump-1 vibration was checked, trend maintained steadily.
 Cooling tower-5 and 4 vibration has been checked after PM checks done by MMD, trend
maintained steadily.
 HRSG-1 all drain and vent valves were checked for the detection of passing valves.

8.6.3.3 Following performance test related jobs completed
 Nil
8.6.3.4 THERMOGRAPHY
 Nil.
8.6.4 Statutory Requirement:
 Phase-I, all hoist and lifting tools testing done

 BOP Safety valves testing done
8.6.5 Overhauling Schedule:
a) Rotary Equipments.
 Nil.
b) Static Equipments:
 Nil
8.6.6 Cost Reduction Activities:

 Nil
.
8.6.7 Shutdown jobs:
Following GT-1 shut down jobs completed
 GT#1, vent fans inspection done

 GT#1, False drain valves, porostone filters, atomizing air bypass valve inspection done
 GT#1, inlet air filter removal, cleaning & installation done
 GT#1, vg dampers checking done and common damper operation problem rectified.
 IGV cleaning done
 electrical co-ordination for OME#2, Motor replacement
 Purge air check valves replacement done.
Following HRSG-1 shut down jobs completed
 Guillotine diverter damper door gasket replaced

 HRSG#1, DD Seals and exhaust duct inspection done
 HRSG#1, CPH safety valve servicing done, leak observed and dummied
Following GT-2 shut down jobs completed
 Gt#2, ESD valve actuator removed for inspection, valve freeness checked, lubrication done
and found ok.
 GT#2 gas skid gas main inlet valve manually operated actuator replaced
 Flow divider discharge piping ferrule leaks for 11, 10 combustion chambers rectified.
 GT#2, Fuel oil high pressure filter(secondary) replaced and y-strainer cleaned
 GT filter inspection was done

 GT#2, Vent fans checking was done, EF Fan belts replaced.

 Water injection hoses ferrule leaks arrested for gt-2 (inside turbine compartment).
 Liquid fuel system purge ferrule leaks arrested.
 Return line PRV in the lube oil skid of warren pump in GT-2 to be replaced.
 Exhaust duct inspection done for gas turbine-2.
 Gas turbine #2A, IGV Cleaning done.

 Nil
 STG, Lube oil accumulator pressure checked and charged.
8.6.8 Break down Maintenance:
 Effluent disposal pump - B overhauling done.
8.6.9 Modifications:
 Phase #1 Effluent line Modification done(connected to phase#3 to effluent pond)

 GT #1 ,Naphtha/HSD skid ,false start pump discharge line modification done
 Dm Water line From Phase#2 to Phase#1 Dm tanks Area Inter connection completed.
 preservation line for phase#1 hrsgs from phase#2 completed
8.6.10 PTW against Maintenance Request:

 Housekeeping and 5S Jobs
 Gland leaks
 Fabrication Jobs
 Plant housekeeping jobs
 Housekeeping jobs at container area
 Scrap segregation at container area
8.7 Phase: 1 Electrical Maintenance
 Ware house new lighting pole fixed and kept in service.

 Canopy Arranged for SST-3 Transformer Bus duct.
 During PM checks it is found that SST-4, 415V Breaker Closing coil failed and replaced
with and kept in service.
 Warehouse power module DOL circuit prepared in FF MCC.
 DM Transfer pump -1 VFD controls hooked up to DCS & trail run taken. VFD settings
noted down.
 220KV Switch yard, Disturbance recorder for Line-2 alarm reset.
 ACW-3 motor currents measured as per operations request.
 GT-2 transformer oil circulating pumps trail run taken for oil leaks inspection.
 In Control room T5 lamp fitting fixed for trail purpose.

 River water ACW/CW Pipe lines Cathodic protection, Shrubs and bushes removed at CP
system accessing points.
 CEP-A motor channel fault problem attended and found control fuse blown. Control fuse
replaced and found normal.
 GT#2 Transformer total tightening done for arresting the oil leaks. During this job oil
pump#2 replaced with spare pump.
 GT-2 transformer cooling fan motor-3 replaced with spare and kept in service.
 GT#2 transformer oil level very low MOG alarm operated in DCS. Conservator filled with
filtered transformer oil up to 35˚C level.
 After MMD PM checks, CT-9 fan motor Trail run taken and coordinated with operation
Dept.
 Neutralization pit waste water disposal pump-A, DM plant starting problem rectified.
 MOV4067 open torque tuned and rectified.
 Welding Machine supply connections given at various locations as per MMD request.
 Welding receptacle MCB’s replaced at DM plant area and Power block VFD area.
 At main gate, electrical cables rerouted and dressing done due to cement flooring work
taken up civil.
 GT-1 Gas skid Condensate sump pump, trail run taken.
 Warehouse telephone cable rerouting coordination with DYNarayana Contractor.
 CT Fan-11 Module SFU replaced with spare.
 Dewatering pump arranged at various locations as per MMD and DM plant request.
 All Lighting panels inside Power Block sealing done for water proofing.
 Lighting material arranged at township, were shifted to Plant.
 Lighting arrangement done as per MMD request at various locations.
 Grinding Machine Repaired as per MMD Request.
 Intercom number 310 arranged in Admin 1st floor to Mr. Ranga Rao.
 Power consumption measurement in TCC-1 motors coordinated with operation people.
 Ware house power cable burnt at H2 cylinder storage area. Temporary power supply
extended to warehouse.
 VFD AC units duct dampers partially closed at VFD-A area as per operations request.
 DM plant Feed Pump- C motor Local/Remote selection Problem Rectified.
 DM plant Degasser Blower-A motor Starting Problem Rectified.
 GTG - 2, 220 KV double break Isolator Earth Switch towards transformer operation
Problem rectified.
 Ferry 11KV DP structure painting coordination with DYNarayana.
 Township, 11KV DP structure painting coordination with DYNarayana.
 GT-2 OME-2 starting problem attended and found B-ph fuse blown, replaced the same.
 STG Sump pumps 1&2 Control circuit problem rectified.
 IAC-3, load checking at 50& and 100% loading as per operation people request.
 TB Replaced for Tank form Storm water pump Motor and fixed and trail run taken.
 STG air washer unit cooling water pump-1rotor machined and fixed.
 SWYD Battery Room Exhaust Fan Contactor replaced.
 ACW Pump-3 motor isolator failed and replaced with spare.
 HPBFP VFD PAC-1 unit tripped on HP/LP and found condenser fan motor failed and sent
for repairing.
 MVWS diesel engine -1 stack-B new batteries arranged and failed batteries returned for buy
back.
 HPBFP VFD PAC-2 blower Motor belts replaced.
 Naphtha spillage pump-2 starting problem rectified.

 As per IT department request, UPS supply wiring modification done at admin building.
 Spare motor PM is under progress in store.
 Jockey pump-6 motor currents checked as per operation request.
 Tank form, HSD Forwarding pump-B,GT-1 starting problem rectified.
 GT#1 Hydraulic pump(88HQ) motor currents measurement as per operation people
request.
 Jockey pump-6 motor trip reset coordination with operation.
 GT#2 stator compartment inspection done.
8.7.2 Scheduled Maintenance
Following Preventive Maintenance jobs completed

 Battery, Station
 Battery, Switch Yard Battery Bank
 Battery ,UPS- A (Replacement with Ni-Cd Batteries-May 2010)
 Battery ,UPS -B
 Battery, River Water Intake Pump house.
 Battery, Gas Turbine Generator 1
 Battery, Gas Turbine-2
 Battery, MVWS Engine-1
 Battery, MVWS Diesel Engine -2
 Battery, MVWS Diesel Engine -3
 Battery, HVWS Diesel Engine
 Battery, Emergency Diesel Generator
 Battery, Switch yard PLCC
 Battery, Switch yard SCADA
 SST-3 Transformer PM checks
 SST-3, 6.6 KV Breaker PM checks
 SST-3 415V Breaker PM checks
 SST-4 Transformer PM checks
 SST-4, 6.6 KV Breaker PM checks
 SST-4 415V Breaker PM checks
 Motor, Auxiliary Cooling Water Pump-C PM
 Motor, Cooling tower make up water pump - B
 Motor, Clarified water pump - A PM
 Motor, D M feed water pump-C
 Motor, Service /Portable water pump-B at DM plant
 Motor, Closed circuit Cooling Water pump - 2
 Motor, CCR HVAC cooling tower -2 Fan
 Motor, CCR HVAC cooling water pump -2
 Motor, Sump pump - 2 in STG area
 Motor, River water intake Pump - A PM
 Motor, River water intake Pump - B PM
 Motor, River water intake Pump - C PM
 Super lubricant metering Pump - 2, GT#1
 Super lubricant metering Pump - 2, GT#2
 Condensate sump pump, GT-1 in Gas skid PM
 UAT-2 transformer PM

 Motor, Condenser CW circulating Pump- B Greasing done

 Motor, Condenser CW circulating Pump- C Greasing done
 MVWS Pump-4 & MVWS Pump-5 Greasing done
 HVWS Pump-8 & jockey Pumps-6&7 Greasing done
 Motor, Condenser Vacuum pumps - A&B Greasing done
 Motor, Air compressors A,B & C (Instrument & service air) Greasing done
 Spare Generator Rotor IR/PI Measurement.
 UAT#1 channel fault problem in DCS rectified. Control supply fuse replaced.
 River water ACW/CW Pipe lines Cathodic protection readings taken.
 Switchyard, Generators, Transformers monthly checks
 HPBFP VFD and AC Units Filters, Evaporators cleaning
Jobs carry forward from last month

 PCC, 415VUnit Switchgear -2 (18/10/2009)
 MCC, Gas Turbine -2 (16/10/2009)
 MCC, HRSG 2 (30/10/2009)
 All transformers oil DGA testing.
8.7.3 Following condition monitoring jobs completed

 Nil

 Nil.
Following equipments overhauling completed.

a) Rotary Equipment
 Motor, Oily water sump pump-1 tank form.
 GT-2 CO2 tank area Dewatering motor.
 AHU motor(spare)
 CCR HVAC-1 compressor cooling tower fan blower motor.
 GT-2 transformer cooling fan motor-3.
b) Static Equipment
 Nil
8.7.6 Cost Reduction Activities:

 Nil
8.7.7 Break down Maintenance:

 Nil
8.7.8 Modifications: Nil

 Housekeeping Jobs
 Panels’ surface cleaning.
 Cables and light scrap identification returned to stores as part of 5S.

8.8 Phase: 1 C&I Maintenance
8.8.1 Following Preventive Maintenance jobs completed
 Plant critical Systems Hardware LEDs healthiness checks PM.

 GT-1&2 Mark V Processors alarm diagnostic checks PM.
 GT-1&2 Mark V and DCS Printers PM.
 DCS SUs, PUs, Plant Bus and Terminal Bus Power supply PM.
 DCS and Mark V <I> Stations and DCS Operating Terminals cleaning PM
 DCS, STG HMI and Mark V Alarm Diagnostic checks PM.
 STG ES, HMI and Printers function checks PM
 STG PLC control Panels inspection and cleaning PM
 DM Plant PLC HMI and Panels cleaning PM
 CCR Notified fire protection system Alarm diagnostic checks, Printer & Repeater PM.
 Weather Monitoring Station Instruments function checks PM.
 GT-1&2 Evaporator Cooler PLC HMIs PM
 GT-1&2 EC Tank Level Gauges cleaning PM
 HRSG-1 SWAS pH Analysers calibration PM.
 HRSG-2 SWAS pH Analysers calibration PM.
 HRSG-1 SWAS Conductivity Analysers calibration PM.
 HRSG-2 SWAS Conductivity Analysers calibration PM.
 SWAS Silica Analyser calibration PM.
 SWAS Hydrazine Analyser calibration PM.
 HRSG-1 NOx Analyser calibration PM.
 HRSG-2 NOx Analyser calibration PM.
 HRSG-2 SPM Analyser calibration PM.
 Instrument Air Drier Control Panels cleaning PM
 RW and CW Chlorine leak Detectors PM.
 RW and CW Chlorine adsorption system Chlorine leak Detectors PM.
 Fire water Pump house Fire protection Panel PM
 Weather Monitoring station Instruments and Panel cleaning PM
 Common Gas skid Gas Chromatograph GC, FC, HMI and Instruments PM.
 Master Instruments function and charging checks PM.
 IAC & EDG rooms Fire system Manual Call Points PM
 Common Gas skid heater Panels 1, 2 & 3 PM
 CT Chlorination system Relay Panel PM.
 GT-1 Evaporator Cooler tank Level glass cleaning PM
 GT-2 Evaporator Cooler tank Level glass cleaning PM
 DM Plant MB - A & B Flow Transmitters calibration PM
 DM Plant SBA - A & B Flow Transmitters calibration PM
 DM Plant WBA - A & B Flow Transmitters calibration PM
 DM Plant ACF - 1A & 1B Flow Transmitters calibration PM
 STG Vacuum Pumps-1&2 Rotameters PM
 HRSG-1&2 NOx Panels AC function checks PM
 GT-1&2 Methane leak Detector Indicators PM
 HPBFP-A, B and C Instruments and Control Panel PM
 GT-1&2 Evaporator Cooler system Solenoid valve Coils inspection and protection

 GT-1 Defective Exhaust Thermocouple No.14 replaced with new.

 GT-1 Cooling Water line WTTD reading erratic reported. Replaced the defective Cable and
found working normal.
 GT-1 Spark plug Power supply defective Cable replaced with new.
 GT-1 Air operated Valves and LFBV strokes checks done.
 GT-1 45HT-3,7&9 Methane Detectors replaced with new, calibrated and found working
normal.
 GT-1 Mark V Timers and Counters modified file downloaded in coordination with GE TA.
 GT-1 Gas purge Pressure showing erratic reported. Defective Cable replaced, Transmitter
calibrated and found working normal.
 GT-1 Air inlet filter DP Transmitter impulse line checked for any condensate and found
none. Manometer also installed to cross check and found matching.
 GT-1 Super lubricant skid and Water Injection skid Pressure Gauges calibrated.
 GT-2 Bearing No.2 Vibration Sensor BB3 cables disconnected in marshaling rack due to
reading fluctuation. During shutdown loop Instruments tightened and wiring normalised.
 GT-2 CO2 tank Pressure Gauges calibrated as they were showing error.
 GT-2 CO2 tank removed Solenoid Valves serviced.
 GT-2 LFBV Moog Servo Valve filter replaced with new, stroke checked and found working
normal.
 GT-2 False start sump Level Gauge not working reported. Checked and rectified the link
problem between float and inner magnet.
 GT-2 Flow Divider area new Methane Detectors 3 Nos fixed and calibrated.
 GT-2 Gas and Turbine compartment Methane Detectors calibraed and 45HT3 replaced with
new.
 GT-2 LFBV main filter replaced, stroke checked and found working normal.
 GT-2 Liquid and Gas Purge Valves , 20AA and 20AB stroke checked and found working
normal.
 GT-2 CPU fan replaced with spare as its sound was found to be abnormal.
 GT-2 Gas skid ESDV not opening reported. Actuator lubricated and found working
normal. Valve function checked by Mech. Maint. and found operating normal.
 GT-2 CO2 leaks identified from On/off valve Solenoid Valves. Replaced 3 defective
Solenoid Valves with new, serviced remaining Solenoid Valves and arrested the
leak.On/off valves stroke checked from CO2 panel and found working normal.
 GT-2 CW discharge Temperature WTTD showing error reported. Loop tightened and
found OK.
 GT-2 Spark plugs and Cables replaced with serviced one.
 Coordinated for GT-1&2 startups in liquid fuel operation.
 HRSG-1 SWAS LP drum Conductivity Transmitter cable replaced with new and found
working normal.
 HRSG-2 DD not closed alarm coming in hooter panel reported. Close feed back Limit
Switch adjusted and found OK.
 HRSG-2 SWAS LP drum pH Transmitter replaced with new as it was found to be defective.
 DCS some of alarms were not getting rested reported. Replaced the Relay of Rochester
panel hooter with new.
 STG Vacuum Pump-2 Pressure Gauge calibrated as it was showing error.
 HPBFP- C Lube oil tank Pressure Gauges calibrated.

 CT Fans 8 & 11 current reading error in DCS reported. Checked along with Electrical and
found to be normal.
 Wireless communication Radios Antenna relocation done and new cable laid to increase
the audiability. Checked the Radio signal audibility upto Naphtha tank form area and
found working normal. Coordinated with V Link Systems Service Engineer.
 IAC-C CW Solenoid Valve leak reported. Serviced the Valve with new O Ring and found
working normal.
 IAD North side inlet Solenoid Valve passing reported. Checked and found problem is due
to NRV passing. Mech Maint is on the job.
 Main Air Receiver drain Solenoid Valve not functioning reported. Serviced and found
working normal.
 IDBH-2 not starting in stream 1 reported, checked and found all Relays are healthy, trail
run taken and took into service.
 CT Chlorination panel Hooter not working reported. Wiring corrected and found working
normal.
 DM Plant MB-B Solenoid Valve leak arrested.
 DM Plant MB-B middle collector inlet valve Actuator serviced with new Seals and found
functioning normal.
 RW Chlorine leak Detector replaced with new and Electrolyte filled.
 CT Fan No.5 Oil Level Switch low acted reported. Checked and found Switch is working
normal.
 ETP Flow Transmitter not working reported. Checked and found Transmitter Power
supply card is not working to be replaced. Awaiting for spare.
 ETP pH Transmitter calibrated.
 DCS Servers, OWS Power consumption details noted as per ISO 50001 requirement.
 GAIL GC calibration co-ordinated along with Chemist.
 GT-1 all protections acted and tripped reported. Tightened the DTBA & DTBB Power
supply wiring in Mark V and coordinated for GT-1 & STG startup. STG LO Pump header
Pressure Switch set changed from 1.2 Bar to 1.5 Bar (approx).
 DM Plant SBA-B Air release Valve serviced with new Diaphragm and arrested the leak.
8.8.3 Jobs pending for Shutdown:
 GT-1 Bearing-1 Thrust inactive Temperature (BTTI9) showing error to be checked.

 GT-1 CO2 System PLC Lamp Test logic to be modified.
 GT-2 Bearing-3 Journal-1 Temperature (BTJ3_1) showing error to be checked.
 GT-2 Wheel Space Thermocouples TTWS3F02 & TTWS3A01 showing error to
be checked and defective Thermocouple TTWS1FI2 to be replaced with new.
 GT-2 Bently Nevada Bearing No.3 Vibration input signals kept disconnected in Mark V.
Instruments and loops to be checked.
 STG LO Pump header Pressure Switch (PSH017) to be calibrated.
8.8.4 Jobs pending on Spares requirement:
 HPBFP common suction Pressure Transmitter indication not coming to DCS. Defective AI
Card to be replaced (TPR No.146).
 Printer Wipro LX240 80 column for Notifier Fire protection System (PR No.257)
 ETP Flow Transmitter not working. Its Power supply card to be replaced.
 Fuser for DCS Printer, USB Cable extender for STG HMI Printer Communication and

 UPS for Gate Control system in Local Purchase.
9 PLANT MAINTENANCE (Phase-II )

9-1 Status of Work Requests/ Work Orders
Total number of Carried forward Work Requests is : 17

Total number of Work Requests raised in current month : 79
Total number of Work Requests : 96
Total number of Completed Work Requests : 69
Total number of completed Preventive maintenance job is : 147
Sl no Description C&I Elec. Mech.

A Unscheduled Maintenance
1 No of Work Requests: Carried forward from last month 02 00 06
2 No of Work Requests: Raised during current month 07 68 02
3 Total No. of Work Requests 09 68 08
3.1 No of Work Requests Completed 08 68 03
3.2 No of Pending Work Requests: Need Plant Shut down. 01 5 6
3.3 No of Pending/Job in progress Work Requests 01 2 1
3.4 Pending Requests: Pending for Resources 02 2 3
B Preventive Maintenance
4.1 Raised in the Month 64 34 52
Completed during Current month 64 32 51
9-2 Plant Major Maintenance Schedule:
Sl Previous Executed Remarks

Equipment Planned
no
8K parts replaced
1 Gas Turbine HGP June-2013 CI: Jan-2011
with 24K parts
2 Steam Turbine Generator inspection:Jan’11
3 HRSG May-2013 May 2012
3 Steam Turbine Generator inspection:Jan’11
9-3 Statutory Inspections:

 Nil.
9-4 Emergency breakdowns and Repairs:

 Nil.
9-5 Key Issues:

 Nil.
9-6 Phase: 2 Mechanical Maintenance

9.6.1 Following unscheduled maintenance Jobs completed
 Phase-2 portable water removed flow meter re-installed.

 Side stream blower-3, inspection done and Pulley side four bearings replaced.
9.6.2 Following Shutdown Maintenance jobs completed.
 STG CCW pump-2, PM checks and casing leak attended and Casing gasket replaced.
 STG vacuum pump suction strainers inspected, Out of two strainers, one strainer not in
position and reaming strainer all so removed as per Operations and Box up both suction
strainers without strainers.
 Pinhole leak attended, in service water pipe line near GT IDCT fan pipe rack area.
 HRSG, HOT spots Inspected with Vendor, Damaged Expansion joints (HP & RH) are
inspected.
 HP, IP, LP Drum samples not coming in SWAS room, pipe lines checking cleared.
 GT-Ac seal oil pump de coupling and alignment completed
 Gas module-2, west side filter separator downstream isolation valve gearbox inspection
done and replaced the bearing and GB internal part serviced and put back.
 PRCS Stream-1 downstream isolation valve gear box internal part serviced and put back.
 HPBFP-B lube oil bottom cooler flange leak arrested by Cooler flange bolts tighten.
 STG HP bypass upstream drain MOV (FVM 0101) is not operating, this valve is replaced
with new valve.
 GT Gas Module-1 gas skid to Reliance gas skid, pipeline painting done.
 HRSG, DD system total inspection done, south side first accumulator bladder punctured
and 3rd bladder has small blow hole so this are replaced with new one and All Accumulator
charged N2 @110 Bar, and trail taken with four Accumulators, now holding time increased
3 min to 1hr.34 min for 1st cycle and 3hr 34 min for 2nd cycle at DD full open position
9.6.3 Following Preventive Maintenance jobs completed:
 DD Seal Air Fan-1

 IDCT Acid dosing pump#1
 IDCT Acid dosing pump#2
 IDCT Hypo dosing pump#1
 IDCT Hypo dosing pump#2
 GT CCW Pump-2
 GT ACW Pump-1
 GT ACW Pump-2
 Raw Water Booster Pump-2
 Back Wash Pump
 Air Compressor -1(Service air)
 Air Compressor -2(Instrument Air)
 Air Compressor -3(Instrument Air
 Instrument Air Dryer-2
 Instrument Air Dryer--3
 HWG Recirculation pump -1
 HWG Recirculation pump -2

 HWG Blower -1
 HWG Blower -2
 Gas Module#1 Gas Condensate Pump
 Gas Module#2 Gas Condensate Pump
 Caustic Pump-1
 Caustic Pump-2
 Side stream blowers#1
 CT acid dosing pump#1
 CT acid dosing pump#2
 HP Dosing Pump#1
 HP Dosing Pump#2
 IP Dosing Pump#1
 IP Dosing Pump#2
 LP Dosing Pump#1
 LP Dosing Pump#2
 Condensate Make Up Pump-1
 Condensate Make Up Pump-2
 STG CCW Pump-1
 STG CCW Pump-2
 STG CCW Pump-3
 STG North AHU recirculation pump#1
 STG North AHU blower#1
 STG North AHU blower#2
 CCR Top AHU recirculation pump#1
 CCR Top AHU blower#1
 CCR Top AHU blower#2
9.6.4 Modifications
 Phase-1 and Phase-2 DM water interconnection done as per modification request.

 Phase-1 and Phase-2 HRSG fill up line interconnection (Near Phase-2 HRSG area) done as
per modification request
9.6.5 Condition monitoring jobs:
9.6.5.1 Following Scheduled condition monitoring jobs completed
 GT ACW Pump –A
 GT CCW Pump -A

 GT CCW Pump -B
 GTG VG fan-2
 GTG BN fan-1
 GTG TK fan-1
 GTG BL fan-1
 Diverter damper seal air fan- west side
 STG CCW Pump -1
 STG CCW Pump -3
 STG ACW Pump -1
 Boiler feed water Pump-1
 STG main lube oil pump-1
 Condenser vacuum pump-1
 Condenser vacuum pump-2
 CT#1 Cooling tower fan assembly
 CT#9 Cooling tower fan assembly Y
 GTG AC seal oil pump
 GTG hydraulic oil pump-East side
 GTG oil mist eliminator fan-East side
9.6.5.2 Following unscheduled condition monitoring jobs completed
 STG all bearings vibration data has been collected from Turbo supervisory system.
 Condition monitoring of following rotating equipment was carried out as per operation
and maintenance request and reports were sent to the concerned departments with
recommendations for corrective actions.
 GTG AC seal oil pump vibration was checked in coupled condition, 100mm/s of velocity
observed. So solo run has been taken, vibration was 60mm/s. Based on spectrum and
physical observations, recommendations have been forwarded to MMD & EMD. Problem
has been escalated to GE for resolution, being followed up.
 High vibration and abnormal noise were observed from STG Auxialary lube oil pump-1,
spectrum indicates bearing related problem, same was informed to EMD & MMD.
Presently pump kept as standby.
 Coordinated with GE for Bore scope inspection of Phase-2 GTG Compressor.
9.6.5.3 Following performance test related jobs completed

 Nil.
9.6.5.4 THERMOGRAPHY
 After online insulation job, thermograph survey has been carried out on HRSG for
assessing the condition of hot spots in the presence of M/s Thermax.

 All safety valves (Fuel gas system, Hot water system, GT lube oil system, GT air processing
unit, Nitrogen system, STG lube oil system, HRSG top dosing system total-43no’s) testing
done .

 Housekeeping and 5S Jobs
 Gland leaks
 Fabrication Jobs
 Strainers (STG ACW, GT CCW, STG Vacuum Pump) cleaning
9-7 Phase :2 Electrical Maintenance
9.7.1 Following unscheduled Maintenance jobs completed.

 ST Generator end shields shifted from stores to ST Generator Floor
 STG CCW-1 Module side power cable lugs replaced
 STG generator new end shield inspection at STG floor
 GT bay LCC panel annunciation window replaced and tested
 SST-2 Transformer meggering done.
 PLCC code-4 spare signals checked from LKPL to NUNNA
 ECB Lift checking with vendor
 SST-2 Transformer meggering done
 SCADA system hanged in control room. SCADA system rebooted.
 SST-2 Transformer meggering and Bus duct inspection
 Welding machine connection given near HRSG area
 Hot air arrangement to SST-2 Transformer LV Bus duct.
 Switchyard Monthly checks done
 SST-2 transformer charging after LV Busduct IR values improvement
 GT shaft earthing brushes cleaning and inspection
 GT area 24V Hand Lamps & Extension boards arranged for boroscope inspection
 GT 400KV Tr. Bay CB Spring charge problem rectification
 SST-1, 415V Inc. CB Service position status to DCS problem rectification
 BFP-A, 6.6KV Breaker service position status to DCS problem rectification
 SST-2 LV bus duct heaters temporary supply disconnected
 Cooling fan arranged at HRSG DD hydraulic unit for GT startup
 Hot air blower removed from phase-II SST-2 and shifted to phase-I
 400KV GIS-1&2 Energy meters auxiliary arranged for down loading the readings.
 400KV Tower Works MOM Meeting with PGCIL
 400KV Bus Coupler CB Control Checked
 GIS CC Camera's auxiliary supply checked
 Welding machine supply given at stores for mech work

 Extension board Supply arranged for Condition monitor department at Accessory

compartment
 Siprotec relays back up collection
 GT Seal oil pump motor no load trail taken load(5.0A,5.0A,5.0A)
 GT Seal oil pump motor overhauling
 Transformer oil pumping from tank to Spare barrel at GT transformer area
 Oil barrels near GTGSUT are shifted to store.Filtered oil:50ltrs,waste oil:30 ltrs.
 Removed AC Pac unit blower motor checked in GIS
 Station SWGR & Unit SWGR LV Bus duct space heater wiring checked
 6.6KV LCI breaker closing coil wiring dressing
 Station Auxiliary MCC Incomer-1&2, Bus coupler closing interlock wiring checked
 Welding Machine supply disconnected at stores
 6.6KV BFP-A module DC fail indication problem rectified.(Fuse replaced)
 GTG transformer oil samples collected.
 MCWP-C Motor closing circuit checked
 Station DCDB ground fault rectified.
 Station SWGR & Unit SWGR LV Bus duct space heater wiring checked
 Vacuum break MOV (Shangui rotork) tuning done,local and DCS operation checked.
 STG CCW pump motor-1 greasing done as some noise observed NDE side.
 Cooling fan arranged at HRSG DD hydraulic unit for GT startup.
 MOV P001 (Shangui rotork) tuning done, local and DCS operation checked.
 Lighting compliments rectification at ECB Building
 GIS SCADA Systems Inverter-1 fault rectification with vendor
 P-2103B Sump pump motor Control circuit problem rectified
 GIS SCADA Hanging problem rectification with Vendor
 400KV STG Bay Earthing points tightness done
 STG Excitation panels cleaning and inspection
9.7.2 Following Preventive Maintenance jobs completed.

 Lube oil compartment Vent Fan 88BL-1 Motor PM,
 Lube oil compartment Vent Fan 88BL-2 Motor PM,
 Load Compartment vent fan 88VG-2 Motor PM
 Station Batteries stack-B PM
 Cooling air Fan Motor -88BN-1 PM done
 Station Batteries stack-A PM
 UPS Batteries PM
 400KV Line-1&2, Bus Coupler Circuit Breakers PM
 400KV Line-1&2 Tower Circuit tightness PM
 400KV Tra. Bay for GT & Bus Coupler Circuit Breakers PM
 400KV Line-1&2, ST Circuit Breakers PM

 Switch Yard Battery Bank Stack-B PM

 EHC Hydraulic Oil pump-1 Motor PM
 SWYD Battery Bank-B PM
 PLCC Battery Bank PM
 BN VENT FAN#2 Motor PM
 EH PUMP(HYDRAULIC) -2 Motor PM
 Control room & Excitation AC Units PM
 BN VENT FAN#2 Motor PM
 LCI and GIS PAC Units PM
 Vacuum pump seal water pump-2 Motor PM
 EH REGENARATIVE PUMP (HYDRAULIC) Motor PM
 EH CIRCULATION PUMP (HYDRAULIC) Motor PM
 GT CCW PUMP-2 Motor Greasing
 MAIN COOLING WATER PUMP-2 Motor greasing
 Stores spare motors PM
 PEECC batteries PM
 EDG batteries PM
 ECB O&M Office UPS batteries PM
 Software CD's & Manuals list prepared
 Telephone exchange AMC & PM
 HRSG Stack Damper PM
 MAIN COOLING WATER PUMP-2 Greasing
 HRSG Stack Damper (PM)
 Switchyard, Generators & Transformers Monthly Checks
9.7.3 Following Condition monitoring jobs completed.

 All Critical motors current readings as part of condition monitoring.
 Weekly Changeover Schedule follows up.

 Nil
Following equipments overhauling completed.
a) Rotary Equipment:
 GT Seal oil pump motor overhauling done
b) Static equipment : Nil
9.7.6 Cost Reduction Activities : Nil

9.7.7 Following Shutdown Maintenance jobs completed.

 Line-1 & Line-2 Energy meter temporary supply arrangenent for down loading the
readings
 GT Shaft voltage monitoring brushes Inspection and cleaning done
 6.6KV LCI breaker closing coil wiring dressing done
 400KV Over head line 1&2 tower circuit tightness checked
 400KV Circuit Breakers and LCC Panels cleaning done
9.8 Phase# 2 :C & I Maintenance
9.8.1 Following Preventive Maintenance jobs completed.
 GT Gauge Panel cleaning PM

 GT HMI CPU and Monitor PM
 Mark Vie Diagnostic Alarm checking
 Mark Vie Jan'13 Copy into External Hard disk
 GT Mark Vie Panels, housekeeping at PEECC PM
 GT Mark Vie Printer PM
 GT OSM CPU and Monitor PM
 Fire protection CO2 PLC Panel PM
 CO2 tank level gauge PM
 GT Hydrogen Analyzer moisture separator silica gel condition inspection and
sampling system leak check PM
 GT GC Analyzer Helium pressure checks PM
 GT Offline wash skid PLC PM
 GT IDCT-2 Vibration and LO Level Switch PM
 DCS Jan'13 data to be copy into DVD.
 CCW Expansion tank Level Transmitter calibration PM
 GT CCW discharge line pH Transmitter PM
 STG DEH Panel, Power supply, I/O card status, OWS Server , ES PM
 STG Switch and Gauge Panel cleaning PM
 STG Hydraulic line filters replacement PM
 STG Lube oil system inst PM
 DEH software database latest back up to be copied in to CD.
 CCW Expansion tank Level Transmitter function check PM
 DCS Critical Instruments and Hardware healthiness checks RIO Panel PM
 PGP server, PGP client servers, monitor cleaning PM
 DCS Power Distribution board inspection and LED status checking PM
 Gas skid Dew point Heater-1 Instruments Temp gauge, Level switch, igniter PM
 Gas skid Metering system instruments PM
 Gas skid Gas chromatograph PM
 Gas skid Gas Flow computer PC & Printer PM
 Gas skid GC Analyzer Helium pressure checks PM
 HWG Servo Motor lubrication PM
 Air Compressors A, B & C Panel PM
 Air Compressors A Instruments PM
 Air Compressors B Instruments PM

 Air Compressors C Instruments PM

 Instrument & Service air Header Auto drain valve PM
 HRSG SWAS Conductivity Analyzers PM
 CEP Cat ion conductivity Analyzer PM
 CEP pH Analyzer PM
 SWAS Panels PM
 SWAS sample line flushing PM
 HRSG Nox, CO and SO2 Analyzer PM
 CW discharge line pH Transmitter PM
 Smoke, Heat Detectors installed in STG building PM
 CCR Aragonite panel PM
 Fire panel CCR PM
 GIS Fire panel PM
 CWP house Fire panel PM
 STG Fire protection Panel PM
 Fire Alarm repeater panel PM
 ECB Cable spreader room Deluge instruments PM
 UT-2 Deluge Instruments PM
 UT-1 Deluge Instruments PM
 Gas skid GC Analyzer Helium pressure checks PM
 Gas skid PLC room AC inst PM
 SWAS Room AC inst PM
 CEMS Room AC inst PM
 Calibration Instruments function checks PM
 24 V Power supply units healthiness checks
 Gas skid PT and TT Calibration
 Swas silica analyzer PM
 GT GC Analyzer Helium pressure checks PM
 CW chlorination system, Cl2 leak detector healthiness checking PM
 Diverter Damper Limit switch and Position Transmitter PM
9.8.2 Following Unscheduled Maintenance jobs completed.
 USM, GC570 Spares inspection done.

 STGDEH SOV's spares inspection done.
 Fire repeater panel outside Relocated Junction box signal cable identification tags fixed.
 HRSG HP, IP, LP O/L Steam Pressure transmitters calibration reports updated.
 HRSG Nox analyzer and Gas skid PT, TT Calibration records updated.
 Gas reports copied
 Mark Vie data copied.
 Co-ordination with Walky-talky vendor
 Mark Vie Jan'13 History data Copied into External Hard disk
 APPCB and dash board Condition Monitoring done.
 GT and Gas skid GC helium pressures checked.
 IDCT Forbes marshal vibration indicator material inspected.
 APPCB and dash board Condition Monitoring done.

 GE CSA material inspection done.

 Gas reports copied
 Gas skid GC analyzer helium pressure checks done.
 Calibration instruments charging done
 RGTIL Gas composition value's updated in FC.
 HRSG HP Drum Pressure Transmitters calibrated.
 HRSG IP Drum Pressure Transmitters calibrated.
 Fire protection CO2 PLC Panel PM Done and Battery backup protection also checked ok.
 HRSG LP Drum Pressure transmitters calibrated
 GT all Exhaust Thermo couples opened and physical inspection done.
 DCS Jan'13 History data copied into DVD.
 GT Exhaust Thermo couples physical inspection done and found no 8 and 27
Are got damaged both are changed with good elements ok.
 All Radio's listing done.
 All systems IP address and Running OS noted.
 Weekly updated calibration reports inspection done.
 Diverter Damper Oil Pump starting frequently Job co-ordinated with MMD
 DEH software database latest back up copied in to CD.
 HRSG NOX and CW Discharge PH Analyzer calibration reports updated.
 DD Spares Review done.
 New Solenoid valves 3 no’s replaced with new in Diverting Damper skid.
 To diagnosis the pressure drop
 ECB Cable spreader room Deluge instrument Pressure switches calibration reports updated.
 Gas skid empty helium cylinder handed over to stores for refilling.
 DCS Printer cartridges Material inspection done.
 GE-TA carried out Mark Vie antivirus updating , Net work security TIL-1881 implemented.
 Temperature matching issue & For SRV/GCV Tripping issue new soft ware loaded,
but not successful.
 Gas skid GC Analyzer calibration done.
 UT-1, UT-2 Deluge instruments Pressure switches calibration reports updated.
 RGTIL Joint calibration followed with Reliance people at M&R station.
 IP Stop valve and control valves stroke checks done.
 RGTIL Joint cal reports updated.
 Scandura Pressure calibrator handover to stores for Re-calibration.
 GT SRV, GCV-1, 2, 3 and Purge valves stroke checks done for plant start-up.
 Plant start-up jobs co-ordinated.
 SWAS All sample lines flushing done and sample flows adjusted.
 AC’s Maintenance work followed with AC Vendor.
9.8.3 Jobs pending for Shutdown:

 GT Bearing no-02 shaft vibration (X-probe) reading erratic to be checked.
9.8.4 Jobs pending on Spares requirement:
 GTG Solenoids for ACW discharge filters self cleaning drain system (PR No.142)
 BSL-310(COMMUNICATION CARD) problem for fire panel in MCW area (PR NO: 217)

Genting Lanco Power Monthly Maintenance Report

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Genting Lanco Power Monthly Maintenance Report

Hochgeladen von

Copyright:

Verfügbare Formate

Genting Lanco Power (India) Private Limited

Lanco Kondapalli Power Plant

Monthly Maintenance Report

8 PLANT MAINTENANCE (Phase-I)

Sl no Description C&I Elec. Mech.

Lanco Kondapalli Power Project Page 1 of 22

8-2 Plant Major Maintenance Schedule:

Sl Previous Executed Remarks

8-3 Statutory Inspections:

8-4 Emergency breakdowns and Repairs:

8-5 Key Issues:

8.6 Phase: 1 Mechanical Maintenance

8.6.1 Following unscheduled Maintenance jobs completed

 HRSG#1, MOV-3022, gland leak arrested.

Lanco Kondapalli Power Project Page 2 of 22

8.6.2 Scheduled Maintenance:

Following equipment Preventive Maintenance jobs completed.

 Cooling tower fan assembly, CELL No-1.

8.6.3 Condition monitoring jobs:

8.6.3.1 Following scheduled condition monitoring jobs completed

 HP / IP Boiler Feed water Pump – B

Lanco Kondapalli Power Project Page 3 of 22

 Cooling tower fan assembly , CELL No-1

 Raw water intake pump-B

8.6.3.2 Following unscheduled condition monitoring jobs completed.

 Jockey pump-6 vibration on slightly higher side, trend maintained steadily.

Lanco Kondapalli Power Project Page 4 of 22

8.6.3.3 Following performance test related jobs completed

8.6.4 Statutory Requirement:

 Phase-I, all hoist and lifting tools testing done

8.6.5 Overhauling Schedule:

8.6.6 Cost Reduction Activities:

Following GT-1 shut down jobs completed

 GT#1, vent fans inspection done

Following HRSG-1 shut down jobs completed

 Guillotine diverter damper door gasket replaced

Following GT-2 shut down jobs completed

Lanco Kondapalli Power Project Page 5 of 22

 GT#2, Vent fans checking was done, EF Fan belts replaced.

Following HRSG-2 shut down jobs completed

 STG, Lube oil accumulator pressure checked and charged.

8.6.8 Break down Maintenance:

 Effluent disposal pump - B overhauling done.

 Phase #1 Effluent line Modification done(connected to phase#3 to effluent pond)

8.6.10 PTW against Maintenance Request:

8.7 Phase: 1 Electrical Maintenance

8.7.1 Following unscheduled Maintenance jobs completed

 Ware house new lighting pole fixed and kept in service.

Lanco Kondapalli Power Project Page 6 of 22

Lanco Kondapalli Power Project Page 7 of 22

8.7.2 Scheduled Maintenance

Following Preventive Maintenance jobs completed

Lanco Kondapalli Power Project Page 8 of 22

 Motor, Condenser CW circulating Pump- B Greasing done

Jobs carry forward from last month

8.7.3 Following condition monitoring jobs completed

8.7.4 Statutory Requirement:

8.7.5 Overhauling Schedule:

Following equipments overhauling completed.

8.7.6 Cost Reduction Activities:

8.7.7 Break down Maintenance:

8.7.8 Modifications: Nil

8.7.9 PTW against Maintenance Request: