UNCHAHAR BTF REDUCTION ACTION PLAN 2009-2010

SHORT AND LONG TERM MEASURE

NTPC-UNCHAHAR

NTPC UNCHAHAR- 5*210 MW UNITS

UNIT Date of Commissioning Boiler RLA Study Carried out OCT-2003 at 88896 running hours OCT-2002 at 82067 running hours Running hrs as on 31.03.2009 133074.61 hrs Last O/H

Unit-1

21.11.1988

20.07.08 to 05.09.08 03.06.07 to 10.07.07 04.07.08 to 07.07.08 [For license renewal] 07.04.08 to 02.05.08 10.05.07 to 30.05.07 30.10.08 to 26.11.08

Unit-2

22.03.1989

134397.50 hrs

Unit-3

27.01.1999 22.10.1999 28.09.2006

68215.00 hrs 75123.21 hrs 19013.68 hrs

Unit-4
Unit-5

NUMBER OF TUBE LEAKAGES

YEAR 2000-01 TOTAL TUBE LEAKAGES 6

2001-02
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

4
5 10 8 5 6 13

2008-09

16

AREAWISE BTF SINCE 2000-2001

1, 1% 1, 1% 2, 3% 2, 3% 1, 1% 14, 19%

Water Wall LTSH Steam cooled Wall

12, 16%

Screen Tube
6, 8%

Economizer RH SH vent line Final SH

17, 24%

Platen SH
16, 23%

RH spacer tube
1, 1%

Supply Tube

BTL area wise 2000-01 to 2008-09

Unit/ Area Unit-I Unit-II Unit-III Unit-IV Unit-V Screen WW LTSH SCW Tube 3 2 6 2 1 2 0 3 1 0 3 1 4 4 4 0 1 0 0 0 Pent Eco RH FSH PSH house 7 2 2 4 2 6 3 1 1 1 1 0 0 0 0 0 0 1 1 0 1 1 0 0 0
Supply Tube/s pacer

Total 24 11 17 13 8

1 1 0 0 0 2

Total

14

16

17

12

73

BTL area wise 2008-09

Unit/ Area Unit-I Unit-II Unit-III Unit-IV Unit-V 01 01 02 01 02 01 02 02 01 Screen WW LTSH SCW Tube Pent Eco RH FSH PSH house 02 01
Supply Tube/ spacer

Total 02 01 04 03 06

Total

02

05

07

01

01

16

BTL cause wise 2000-01 to 2008-09

Unit/ Area Unit-I Unit-II Unit-III Unit-IV Unit-V Total Weld Attach Fly ash Steam joint ment erosion erosion failure weld 2 7 9 9 2 1 6 6 24 2 1 1 4 2 1 6 1 1 11 over Old Coal heati joints Eros ng failure ion 6 4 1 2 1 14 2 1 3 6 1 1 2 3 Mat. Fail Total ure 2 1 24 11 17 13 8

73

BTL cause wise 2008-09

Unit/ Area Unit-I Unit-II Unit-III Unit-IV Unit-V Total 02 01 03 04 08 01 03 01 02 01 02 Weld Attach Fly ash Steam joint ment erosion erosion failure weld 01 01 01 01 over Old Coal heati joints Eros ng failure ion Mat. Fail Total ure 02 01 04 03 06

16

CAUSEWISE BTF 2008-2009

overheating, 2, 13%

Weld joint failure, 6, 38%

Weld joint failure Fly ash erosion overheating

Fly ash erosion, 8, 49%

Unit Unit-I Unit-II Unit-III Unit-IV Unit-V Total

Weld joint failure

Fly ash erosion

overheating

Mat. Failure

Total

01

01 01

02 01 04

04 03 01 06 04 08 01 02

03 06 16

BTF STATUS SINCE LAST OH

UNITS Last unit OH 0 to 3 months 3 to 6 months 01 22.12.08 6 to 9 months 9 to 12 & more months Remarks Last leakage22.12.08 02 06.03.2008 12.01.2009 01 04.03.09 03 15.10.08 20.12.08 19.01.09 last leakage 12.01.2009

UNIT-1

20.07.08 to 05.09.08 03.06.07 to 10.07.07 04.07.08 to 07.07.08 [For license] 07.04.08 to 02.05.08

UNIT-2

01 24.07.07

01 26.01.08

UNIT-3

02 26.05.08 22.06.08

01 29.12.08

Last leakage04.03.09

UNIT-4

10.05.07 to 30.05.07

Last leakage 19.01.09

UNIT-5

30.10.08 to 26.11.08

01 09.01.09

01 08.03.09

Last leakage08.03.09

STRATEGIES TO REDUCE FORCED OUTAGES Emphasis on Inspection Detailed inspection as per check list prepared by CCOS to be carried out during overhaul Inspection report to be generated, trending to be done to ascertain rate of deterioration Implementation of recommendations of failure analysis Damage mechanism to be identified and to be eliminated. This will reduce quantum of work 100% radiography of new weld joints Radiography of old weld joints Post work inspection such as alignment of coils, fixing of shields, restoration of clamps/supports

ACTION PLAN FOR REDUCTION OF BOILER TUBE LEAKAGES

Sl No Description 1 2 Mapping of boiler based on earlier BTF. Quality of Argon gas in terms of its purity 99.99% to be ensured to eliminate porosity problem in the weld. Indenting of 99.99% Argon Cylinders Creating gap in inner loop of Platen Super heater in Unit # 2 to avoid expansion restriction Procurement action for SHH -4B (Unit # 5) PO placed on 25.02.09. PO-4000019286. Target Date completed In process

3 4

31.10.2009 PO placed

5
6

Modular Replacement of Eco Coils in Stage-I & II .PO placement. PR-100009596 dated-01.10.08

31.12.2009

Usage of modern tools during O/H. Additional Special tools 31.12.2009 indenting. Indent raised for D-meter with data logger and portable compressor.PR-100016929 and PR-100016929

Providing guide vanes at all elevations of coal compartment in stage-2 and 3 during O/H

OH-2009

ACTION PLAN FOR REDUCTION OF BOILER TUBE LEAKAGES

Sl No 8 Description Additional handling platforms for facilitating modular replacement of eco coil in stage-1,2 and-3.Feasibility offer awaited from BHEL TRICHY R&M CELL. Low Frequency Electromagnetic testing (LFET) is to be used for Boiler tube thickness survey to enhance productivity. (U#1) Standardization of vendors for Boiler Pressure Parts Application of plastic refractory in erosion prone critical location of all boilers. U#2,3,4 Procurement of SA 387 , 12/22 Alloy Steel Plate for U#5 Procurement action for Additional set of cup lock. PR100017250 dated-26.02.2009. Round the clock deployment of executives in critical areas during O/H. 8 executives are required for the same Target Date 31.03.2010

Next O/H

10 11

Under process at NRHQ Next O/H

12 13 14

30.09.2009 30.06.2009 During Next overhauling

Area wise BTL during 2000-01 to 2008-09 I st Pass at UNCHAHAR

Total number of BTL in Pent-Hause-01 U#1-1 U#2-0 U#3-0 U#4-0 U#5-0

Total number of BTL in FSH-2 U#1-0 U#2-0 U#3-1 U#4-1 U#5-0 Total number of BTL in Screen Tube-1 U#1-0 U#2-1 U#3-0 U#4-0 U#5-0 Total number of BTL in PSH-2 U#1-1 U#2-1 U#3-0 U#4-0 U#5-0 Total number of BTL in RH-12 U#1-6 U#2-3 U#3-1 U#4-1 U#5-1

Total number of BTL in W/W-14 U#1-2 U#2-3 U#3-6 U#4-2 U#5-1

Area wise BTL during 2000-01 to 2008-09 II nd Pass at UNCHAHAR

Total number of BTL in LTSH-6 U#1-2 U#2-0 U#3-3 U#4-1 U#5-0

Total number of BTL in Economiser-17 U#1-7 U#2-2 U#3-2 U#4-4 U#5-2

Total number of BTL in SCW 16 U#1-3 U#2-1 U#3-4 U#4-4 U#5-4

Total number of BTL in Supply Tube-2 U#1-1 U#2-1 U#3-N.A U#4-N.A U#5-N.A

SHORT TERM MEASURE

SHORT TERM MEASURE

Implementation of boiler knowledge team recommendations during unit OH. Boiler 100% inspection. Approach platform to all locations up to roof. Quality of radiography to be ensured. Double elliptical shots of side coils , both at 0 0 and 90 0 . More executive to be trained to check edge preparation, root gap, fitment alignment and radiography of the joints. IBR welder test before deployment. fin welding by IBR welder. Activity based inspection with protocol. Quality of agency and skilled manpower identification for specific work. Agency selection based on quality of work, performance and resources. Mapping of boiler based on earlier BTF. Round the clock manning during OH to ensure quality check before final fit-up.

 Focus on opportunity maintenance regarding inspection of critical location prone to flue gas erosion based on earlier failure. Alignment of coil restoring in original position and related clamps/support restoration need to be focused to ensure quality of work. Quality of filler wire and electrodes to be ensured including preheating in the oven before use. Quality of Argon gas in terms of its purity 99.99% to be ensured to eliminate porosity problem in the weld. A team of quality persons to be identified in the regional level and their services to be utilized during OH. More executive on round the clock basis may be deployed on job for in depth boiler inspection and quality checks. Attachment weld by HP welder and DP test to be ensured. Water wall transition tube root welding radiography. Restoration of damaged thermocouples for measurement of metal temperature. Replacement of balance bottom bends of Reheater rear coil.

SHORT TERM MEASURE

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Location : Economizer & LTSH BTF (2000-08) : 32% Reason of BTF : Erection/ Maintenance weld joint failure, Ash erosion, Fatigue failure. ACTION PLAN Location of in-situ inspection to be marked on drawing. In situ inspection of three tubes from top and three tubes from bottom of both banks for thickness survey 100%. Based on extent of erosion, coils to be lowered /raised for full inspection. Misalignment of coil to be corrected. Coils to be lowered in pairs by removing pins. Full alignment to be ensured after coils are restored. Radiography of at least 10% old joints to be done & based on defects %age may be increased. All foreign material lying in between tubes to be removed. 100% inspection of Eco header stubs. 100% radiography of new joints. Damaged/ eroded hanger clamps to be replaced in the coils which are lowered for inspection/ repaired.

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Location : Water Wall, screen tube, supply tube & SCW BTF (2000-08) : 44% Reason of BTF : Weld joints, Steam erosion, Coal erosion & Attachment weld failures ACTION

Tube thickness survey at 6 elevations in S panel, water wall & Ext. water wall burner panels, goose neck, tubes around manholes and around wall blowers. Replacement of coal nozzle assy. In-situ inspection of all the tubes. Based on extent of dent, erosion, tubes to be replaced. Misalignment to be corrected. Attachment weld failures inspection. DP test of attachment. Restoration of all supports cut during repair & welding DP test.

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Restoration of all supports cut during repair & welding DP test. Overhauling of soot blowers & pressure setting. Fin welding by IBR welder. WW tube root radiography (started from-2008 OH). Alignment of burner tilt & synchronized movement of SADC. Healthiness of air guide vanes, coal nozzles & coal nozzle tips. Condition of oil & air compartments. Inspection of starting and terminal points of fin welding. Inspection of attachment welds in bottom dead chamber.

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Location: Super Heater+ Platen BTF (2000-08) : 07% Reason of BTF : Overheating, Material failure ACTION

Physical inspection of SH tubes for signs of bowing and overheating. Boiler filling with deaerated water only. Maintaining dissolved oxygen within limit at condenser outlet and dearator outlet. Check for mechanical rubbing near spacer tubes, clamps etc. Alignment of panels, check for flexible connectors, bow and for sign of over heating. Replacement of DMW joints in a phased manner. Inside oxide thickness measurement to be done and tube showing highest oxide layer thickness to be cut and sent for following tests-hardness, oxide thickness, microstructure and creep test. Inspection of flexiable connectors and replacement of broken connectors.

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Ensuring controlled cooling of boiler during shutdown and monitoring expansions during startup. Inspection for overheating of seal bend and crown plate. Inspection for erosion near the roof. Constant monitoring of steam / metal temp in SH NDT of all joints by radiography, welded during OH and breakdown. Inspection (DPT) of pent house vents and drains. Pent house floor repair and insulation survey. Inspection of spacer tubes.

ACTION PLAN FOR REDUCTION IN BOILER TUBE FAILURE

Location: Re heater + RH spacer BTF (2000-08) : 17% Reason of BTF : overheating ACTION Replacement of overheated tubes of RH by new tubes. Constant monitoring of steam / metal temp in RH Inspection of any mechanical rubbing with supports, or vibration and correction during O/H. Replacement of tubes after excess oxide thickness. ASLD installation for early pickup and to reduce secondary damages in unit-2. While replacement of RH outlet coils, care to be taken for alignment and attachment welding. Inside oxide scale measurement to be done in RH. If inside oxide scales thickness is found to be more than 700 microns, then sample form tube having highest internal oxide scale to cut and should be sent to R&D lab for microstructure and remaining creep life. If internal oxide scale thickness is found less than 700 microns then sample tube need not be cut fo r lab analysis. Inside oxide scale thickness measurement to be done before DMW joints in T22 material and near DMW joints. While replacing overheated tubes inside penthouse, tube along with DMW joints should be replaced.

PRACTICES TO BE FOLLOWED DURING UNIT OH

Steam/ air blowing of new tubes before installation. Sponge ball test of new coils/ bends before installation. All vertical tubes to be cut with grinders only. Immediate capping of tubes after cutting. Deployment of tested cutters for tube cutting All attachment welds to be carried out by tested HP welders. Attachment welding to be done by electrode of 2-2.5 mm size. Pad welding should not be done. All supports / clamps cut during OH for tube repair should be restored to original condition. To ensure quality of work modern tools like bevel cutting machine, panel cutting machine, pneumatic tools to be encouraged.

GUIDE LINES FOR SAFETY VALVES

All ERV`s in MS line and HRH line to be made operational. it is mandatory to keep all ERV`s in service. Spring loaded safety valve in MS line to be serviced in every overhaul. Spring loaded safety valve in CRH/HRH lines to be serviced in two years cycle. Spring loaded safety valves in drums to be serviced in three years cycle. All spring loaded safety valves to be floated by TREVI-TEST during every OH with temperature correction. The safety valves which are dismantled and serviced must be floated at actual steam pressure with temperature correction. If any valves develops passing problem, it should not be gagged. Instead ,it should be attended at the earliest opportunity. Protocol to be made for servicing, floating/Trevi-test of all spring loaded safety valves and ERV`s

LONG TERM MEASURE

LONG TERM MEASURE

Boiler mapping based on last 10 years BTF and its analysis. Boiler scope of work to be revisited based on design requirement and earlier failures analysis. Implementation of modular replacement of ECO and LTSH coils in phased manner. procurement of coils to be initiated. Proposal for making additional platform for modular replacement to be initiated. Rate contract with boiler manufacturer for supply of coils, tubes and bends to reduce lead time of procurement. OH schedule to be freezed for five years and not to be altered. Knowledge team observation and recommendation implementation to be ensured. Qualified agencies to be standardized for pressure part work and selection based on performance and resource. Selection of Vendors need to be improved and tools and tackles and facility extended by the Contractors are to be pre specified. Also manpower deployment quantum to be specified along with, if required, specific individual deployment to be specified for specific work. Development of quality team for pressure part work. Development of HP welder in the region to ensure availability. Low Frequency Electromagnetic testing (LFET) is to be used for Boiler tube thickness survey to enhance productivity.

LONG TERM MEASURE

Agency should mobilize Special tools, advanced / modern T&Ps, bevel cutting machine etc. during Overhauling. Usage of latest or innovative tools for possible time reduction is to be given priority. Replacement of unit-1 reheater rear coils with improved material T-91.Order for 10 coils placed on BHEL. Indent raised for remaining 49 coils.PR300003000 dated 01.05.2009. Replacement planned in 2010-11. Installation of boiler tube leak detection system in unit-2 100% old joints radiography to be completed in next five years. Improved material for coal nozzle for two year running to be explored. Providing guide vanes at all elevations of coal compartment in stage-2. Radiography of DMW joints and replacement. if necessary. Improvement in maintenance practices for quality work. Failure analysis report implementation. For continuous and quality supervision adequate executive manpower may be provided. Exploring the Possibility for imposing clause of incentive and penalty for early/delayed completion of the job in the contract.

List of tools being procured for BMD quality maintenance practices at Unchahar
Description of item
1-Hyd gang jack for APH 2-Tube cutting machine. 3-Portable panel cutting machine. 4-Bevel cutting machines. 5-Search light 6-Plazma cutting machine 7-Pneumatic tools 8-Electric hoist for APH 9-Fork lift. 10-Centrifuge MAB-103 11-Cap lock scaffolding additional material

Purchase indent details

PO-2250078 05.05.2007 PO-6240030,31 19.04.2007 PI-620036 19.04.2007

Remarks-status as on 01.05.09
Material received in Dec-07 [M/S Enerpac] Material received in july-07 [M/S Hitachi] Material received and demonstrated by agency in march-09. PO placed Material received in sept-07 [M/S Bridge gap] Material received and tested. Material received in Nov-07 [M/S Grip hold tools Baroda] Fresh indent raised. Received and in service. Received and commissioned. Material received in feb-08. [M/S British scaffolding]

PI-620036

19.04.2007

PO-8240199 03.07.2007 PO-6250766 10.03.2007 PO-2340208 13.07.2007 PR-100014176 dated 31.12.2008 PO-6340460 18.10.2007 PO-5050181 21.06.2007 PO-6350500 13.11.2007

List of tools being procured for BMD quality maintenance practices at Unchahar
Description of item
13-Pneumatic hand power saw-5nos 14-Pneumatic high speed grinder-10nos 15-Portable air compressure-02nos

Purchase indent details

Indent to be raised by 15.06.2009 Indent to be raised by 15.06.2009 PR-100016649 dated16.02.2009

Remarks-status as on 01.05.09

Under budget vetting

16-D-meter along with datalogger-05nos

PR-100016929 dated 21.02.2009

Enquiry issued9900023865 dated 18.05.09