Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
1 Turbine
Get list of spares
Turbine condition by hand rotation Visual Inspection found OK. Overhauling done by Alignment check. Stock spares at site & Main bearings, thrust bearing, thrust replaced during earlier
a
found Ok. customer. replace if needed during commissioing. shims etc. overhauling by other
party
b Trip Valve spring condition. Working - Conical Spring
Get list of spares
Over speed Tripping mechanism Test & Set Mechanical Ovsepeed trip test Trip valve Spring, trip Lever, Trip
C replaced during
functioning during commissioing Plunger, Trip Adjusting nuts
overhauling
d High speed coupling Check Alignment Shim Pack, Hardware
Trip Solenoid supplie with turbine is not available. If the replaced solenoid fails, spare to be
e Trip solenoid.
Solenoid replaced during overhauling. Found working kept at site
Steam chest gasket, Steam chest
Turbine & accessories gaskets < Keep spares available at site & replace if paper gasket, ESV Bush, Stem
f As per customer, turbine has been tested at rated RPM
condition required during commissioing assembly, Carbon seals, garter
springs, sealant, PTFE tape, anti-seze,
g Turbine BTD Working Replace RTD cables up to FJB RTD Cable
Outputs to be checked during
h Vibration Probe Vibration sensor & cable
commssioning / Send to check Calibration
2 Gear Biox
Gear & Pinion inspection done. Checkd by hand Check Name Plate Speed & original supplied
a Gear Box Internals rotation. Found OK. gear box ratio to identify the issue in speed
Bearing and thrust collar to be inspected. diference
Low Speed coupling is in good condition, all the
b Low speed coupling Greasing, Alignment Grease
hardware is in good condition,
As per present condition, oil leackage from breather
c GB Breather and so drain piping connected from breather to oil
tank.
d Gear box BTD Available and Working fine, old cable used Replace RTD cables up to FJB RTD Cable
Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
3 Lube System
Lube system working fine, system Remove oild oil, tank cleaing & charge new Labour & consumables
a Wrong oil used 400 ltr Oil, ISO VG 68
operated with AOP. oil for lube system cleaning
Cooler tested for water circulation. Found ok. PHE gaskets
Gages, Pressure switches, PT, Level Switch found Pressure Gages, Pressure Switch
b Lube System Instruments Replace instruments
damaged. Available PT is of 0 - 10 bar (Pressure transmitters), RTD
c Lube oil PRV condition Found OK Serice spares of PRVs Service spares for PRV
d Lube oil filters & Strainers Need cleaning / replacement replace Fitlers & strainers Main & Safety Filters & Strainers
AOP and MOP working confirmation Need to check during commissioning.
e MOP not checked MOP pump
by exchanging the pumps. Repalce if required
4 Alternator:
List of spares & services
Alternator- By hand rotation, found
a done for generator
Ok.
1. Bearings reached end of life due to long storage & overhauling
stagnant without roration. Need overhauling, bearing Need to check at No load test. Maintain AVR, Harness, Bearings, bearing
b AVR - MX321.
replacement as recoomanded by Stamford. spares grease, Diodes
2. BTDs working Need to check at No load test. Maintain
c Isolation Transformer Isolation Transformer
3. 05 RTDs woorking. 01 not working. spares
d ALT BTD Replace Cables. Test at No Load
e Alt Winding Temp RTD Replace Generator to TCP cables RTD Cables
Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
5 Control Panel
1. Original Control Panel found replaced with new
Control components. New Siemens make PLC & HMI
installed for which PLC Program code back up &
password is not available.
2. Speed measuring & Control System not evident as
required for Automatic Start-Up & Synchronising
3. Synchronising controls not availble from Auto-Sync
relay
4. Back Pressure Control not evident from the Wiring.
PLC program not accessible to check the logics built. 1. Repalce with TurboSmart Controller &
PLC & HMI, Control Accessories, HMI
a 5. Control Wiring not as rquired for fail safeties Provide newly wired TurboSmart
Speed converter, Speed Inicator 2. Rewire control System for original state
provided originally. with IOs, HMI, Control Accessories.
6. Magnetic Pick-Up Frequrncy to 4-20mA converter with Automatic Speed Control, Auto
check if any accessories from the
not used. GPR used for Speed sensing. Synchronising, Automatic Back-Pressure
panel can be used
7. Sync Bias & Voltage bias control required for Control
Synchronising not used. 3. No Load & Load Test (Commissioning)
8. Automatic Speed control up to RATED SPEED &
AUTO SYNCHRONISING, Breaker Closing Control in Sync
Mode, Power Factor Control, Turbine Back Pressure
Control in AUTO mode not evident from the control
wiring
b Load manager EM6459 withour RS 485
c Hooter
d Synchroscope
e Panel Operation Unable to maintain speed & Sync with Grid. As mentioned above
f Steam Flow Totalizer Calibrate Flow transmitter Steam Flow Totaliser DPT Calibrator
Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
6 Breaker Panel
1. Turbine Generator Neutral Switching Control not Neutral Contactor, Set of Busbars &
1. Isolate Neutral bus bar from ACB.
a Turbine ACB provided in case of Sync Mode hardware, Enclosure for NCB, Power
2. Provide Neutral Contactor
Cables etc.
b PTs Sync Input PT Specs not as required Replace PTs Bus & Generator PTs
Generator Protection relay CT inputs wired from
c CTs Replace CTs Protection Class CTs
Interposing CTs which is not recommanded.
d ACB UV coil - 230 Vac Not wired for fail safe operation New Wiring for Fail safe operation Spare UV Coil
e ACB Closing coil - 24 VDC OK - Spare Closing Coil
f ACB Shunt Trip coil - 230 Vac Trip Coil is of 230V AC Replae with 24V DC Spare Shunt Coil
7 Power evacuation ACB
3 Pole 2000 Amp, Siemens LSIG Protection and Neutral
Testing of ACB for Trip Unit & Manintenance external aganecy for ACB
is directely connected to busbar, Working fine Previous
if required testing & Overhauling
Location changed
8 By Pass PRV & Desuper Heater Station
Overhauling of Control Valve & Accesories,
a Turbine Bypass PRV PRV not in operaton. PRV Manual Bypass being used.
Positioner etc.
Check & Repalce faulty
b Turbine Bypass DSH By-pass De-Super Heaer is not working in Auto mode
components if required
9 Drains & Traps
All are working, but too much rusting is there Overhauling
10 Cyclone moisture separator
1. Check for Cyclone separator component
Unable to check due to damaged compound wall and failure. Repalce traps, byass
Spares as per the
risk, but as per site person, now Roaster is changed and 2. Condensate Recovery system (Pumping,
observation at site
steam quality has inproved Level control automation Panel Field
instruments) to be restored
Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
11 Turbine Exhaust PT
Installed Check during commissioning Exhaust PT
12 Control Valve Spare Exhaust PT
Turbine Control Valve ( MIL ) overhaul by customer and
Optional Control valve integrated to the Volume Booster / Intgrated Governor Steam Inlet line
its working fine. Vollume bustoer is not availabel. 24
Turbine can be quoted separately Valve Assembly modification
VDC solenoide coil is available and installed on valve .
13 Turbine Inlet Isolation Valve
Steam Leakage (Passing) observed Need overhaul Overhauling of Valve
14 Turbine Exhaust Isolation Valve & NRV
Steam Leakage (Passing) observed from Valve & NRV Overhauling of Valve &
both NRV
15 FJB
EOP switchgear is available in FJB, Indication also
Test Circuits Hooter
available, Hooter is missing in FJB>.
16 UPS
UPS for Control panle supply is avilable but not working Repair / replace UPS, Batteries
17 Battery & battery charger for EOP
Batteries, Charger, battery Stand, Electrician for field
Both batteries & Battery Charger are Missing Install Charger Batteies
Connecting leads, field cables cabling
18 Turbine Control Room & Turbine House
a Control panel room dusty Cleaning of Turbine room
b Turbine, Generator, Gear Box not maintained clean Cleaning Labour & consumables
c Air Conditioner not operational Repair / Replace Air Conditoner
Site Visit Report

Customer: Hindustan Zinc Limited, Debari, Udaipur, Rajasthan Date: 01-April-2021

Project # : JOD 60707 AST No.: NA

Obseravation during Site Visit & Action Plan

Sr No Componant Name Current Status (Updated By SSK) Action Required / Remark Required Spares Customer Resources
Issues reported By Customer:
1. Turbine Generator system along with Lube oil system is overhaul by customer and Trials was taken
2. While testing recahes up to rated RPM of Turbine i.e. 3900RPM, but due to some error (may be in the measuring circuits) turbine needs to be taken up to 4200 RPM then only Generator Frequency
reaches rated 50Hz.
3. Voltage generated trying to synch with local grid but not able to synch due to hunting of Turbine speed by +/- 300 RPM from rated Speed.
4. As per customer Steam quality is improved due to change in Roster (Waste heat recovery boiler)
5. Steam pressure will be 25 to 28kg/cm2 (g), and available steam flow will be 8 to 12 TPH.