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Overhauling Surprises of Unit # 4: Electrical & C&I

During the overhaul of Unit #4, several issues were discovered in the electrical, C&I, turbine, and boiler systems. In the electrical system, loss of PLC supply from Unit #4 affected the bottom ash system of other units. Humming sounds were coming from the generator prior to overhaul. The start up transformer tripped due to water in the bus duct. Secondary power sources need to be provided for some equipment during future overhauls. In the turbine system, one primary water pump was producing less flow than the other. Isolating valves on air-cooled water equipment needed maintenance. Condenser water box valves had minor leaks. High temperatures were measured on thrust bearings. Multiple

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86 views4 pages

Overhauling Surprises of Unit # 4: Electrical & C&I

During the overhaul of Unit #4, several issues were discovered in the electrical, C&I, turbine, and boiler systems. In the electrical system, loss of PLC supply from Unit #4 affected the bottom ash system of other units. Humming sounds were coming from the generator prior to overhaul. The start up transformer tripped due to water in the bus duct. Secondary power sources need to be provided for some equipment during future overhauls. In the turbine system, one primary water pump was producing less flow than the other. Isolating valves on air-cooled water equipment needed maintenance. Condenser water box valves had minor leaks. High temperatures were measured on thrust bearings. Multiple

Uploaded by

Sony Rama
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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OVERHAULING SURPRISES OF UNIT # 4

ELECTRICAL & C&I:


During shutdown of BOTTOM ASH MCC, it was found that bottom ashing of
Unit # 5&6 got affected due to loss of PLC supply of Unit # 4.So PM of Bottom
ash MCC was done section wise. C&I has been asked for further study &
modification if possible for system reliability
Generator humming sound was coming at various frequencies prior to
overhauling. It was observed that air gap supporting clamp was in hanging
condition during overhaul of generator
START UP transformer tripped on differential protection on charging after PM
work. Bus duct inspection was done & found IR value zero due to water
accumulation inside the bus duct. It was dried & IR value was improved &
charged
Overhauling of Boiler ACDB was found difficult due to welding DB & lighting
supply of boiler side. Second source is to be provided before second overhauling.
Overhauling of Emergency MCC was difficult as only one supply source was
available for boiler lift.
Second DC source was not available in FOPH, CT MCC, ASH WATER MCC, &
CW PP butterfly valves.
During ATT checking, reset solenoid was not getting resettled. While resetting the
solenoid, turbine tripped. So ATT checking was suspended.
ASH Extraction switchgear breaker remote commission was not through from
C&I side.(It was not through since initial commissioning) Although inter trip was
checked while commissioning the MCC.
Motor trial of CW PP 4B was not possible due non-availability of cooling water
supply (cooling water supply will be available only when pp is running). External
pp was arranged for motor bearing cooling water supply.

Cont

TURBINE SIDE:
Primary water pp 1 flow remains less compare Primary water pp 2 even after
cleaning of cone filter & fine mess filter. Previously NRV passing checking was
done for both pumps & no passing observed.
TG PHE # C was not getting isolated from ACW inlet side. Problem was attended
during complete shutdown of ACW system by replacing valve body seal. It was
cleaned & kept as standby.
ACW # C suction valve has having passing problem & not being attended due
passing of ACW common Inlet valve & CW interconnection valve of Unit # 4
side & Unit # 3 side.
Condenser water box inlet / outlet valve has slight passing problem & not being
attended during overhaul due to passing of CW inter connection valve of Unit # 4
side & Unit # 3 side ( CW PP 4A , 4B & 3C were in stopped condition).
Condenser water box DP was 0.41 / 0.40 kg/cm2 even after tube cleaning.
TD BFP # 4B thrust bearing temp.(T-22) maintains high of 92 0C even after job
was taken by BHEL.
Exciter end coupling guard (brg. No.6) was touching with shaft at 3000RPM.
Same was removed

Cont

BOILER SIDE:

ECO Bypass duct was found full of ash. Diverter damper of PRAPH A / B
was found partial open condition. It was closed & mechanically locked.
All water wall soot blowers stroke length was found disturbed condition.
Stroke length recalibrated.
Staircase inside wind box for SADC checking was not available.
All air preheater baskets extreme end circle at soot blower resting point
erosion found.
All blowers (Air side & gas side) except PRAPH A / B airside blower have
been commissioned. PRAPH A / B airside blowers are getting tripped / not
taking start & some standby blowers are not taking start. All discharge valve
actuators were not operating. Problems have been intimated to EMD.
CC PP # B cavity filling was done first time during overhauling due to
discharge flange gasket leakage.
Water was coming during cutting & welding of water wall tubes at 10.5mtr.
After intensive checking, it was found passing from boiler fill line valves at
turbine end & boiler end in closed condition. Both valves servicing done.
Passing arrested. Drain before manual isolating v/v of boiler fill line &
vent after manual isolating valve at boiler 0mtr are to be kept open
whenever boiler fill pump is to be taken into service.
Reheater inlet header metal temperature has gone high to 80 0C during boiler
external hydro test at 200Kg/cm2 on 31/08/2005. MDBFP was running from
12:00Hrs to 21:30hrs on 31/08/2005 for carrying out external hydro test. BFP
suction temp. had gone up to 112 0C due to prolonged running of MDBFP..
Reheater inlet header temp. was increased due to passing of Reheater spray
line. Reheater tube cutting & welding was affected. Reheater spray station
& super heater spray station drains at firing floor are to be kept open
while doing boiler hydro test.

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