Scribd
Upload
148 views17 pages

Quality Checks During Overhaul

Quality and safety are two essential components of successful overhaul management of a thermal power plant.

Uploaded by

P Koteswara Rao
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
148 views17 pages

Quality Checks During Overhaul

Quality and safety are two essential components of successful overhaul management of a thermal power plant.

Uploaded by

P Koteswara Rao
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 17

Quality Checks During Overhaul

Akin to Man’s Annual Health Checks

Dr. Pothala Koteswara Rao


Managing Director-RaKo Associates
QA Checks Areas

• Boiler Pass 1&2


• Ducts
• Rotary parts
• ESP
• Turbine auxiliaries
• Generator
Role Of QA During Overhaul

• To prepare quality plan before overhaul.


• To prepare QA check lists.
• To involve in critical checks during overhaul.
• To involve in day to day maintenance.
• To carryout non destructive testing.
Boiler Tube Failure Mechanisms

• Erosion
• Corrosion
• Mechanical wear
• Material mix-up
• Weld failures i.e Dissimilar & attachment weld failures
Preventive Measures – During O/H

• 100% visual inspection in all the identified areas


• Deploying IBR qualified welders & use of approved electrodes
• Extensive Tube Thickness survey
• NDT of welds (DPT, RT, UT &MPI)
QA Methodology In Different Areas
• Goose neck region: DPT, Visual inspection and TTS
• RH girdling loops: Visual inspection for dents and distortion of binding
loops
• Economizers & LTSH: Tube Thickness Survey for top, bottom, extreme
coils both sides 1 to 5 tubes and visual inspection for alignment and
erosion.
• LTSH bifurcation tubes: Visual inspection for refractory damage and
erosion & TTS
• RH : Visual inspection for overheating ,cleat rubbing (half reheater) and
TTS & DPT
• Header stub joints: Visual inspection and DPT
• Screen tubes: TTS and visual inspection
• Raiser tubes: MPI / RT of bends and weldments
QA Methodology In Different Areas

• DUCT:
• Deflector plates, damper gates, duct bend portion eco outlet hopper :
• Visual inspection for erosion & cleanliness.
• Rotary parts:
• APH:
• Guide bearing : Visual inspection and level checking
• Support bearing: visual (wear & tear on runner area)
QA Methodology In Different Areas
• PA Fan, FD Fan: Blade alignment and clearances, motor & fan alignment
and blades DPT

• ID Fan:
• Bearing surface –Visual & DPT
• Shaft visual inspection for pitting
• Welding joints and shaft- MPI&DPT
• ESP: Erosion of emitting electrodes, hammer rings, bending of shock bar
and cracking of suspension frame hooks of collecting electrodes
Turbine
• Main turbine (HP,IP and LP) checks
• NDT checks on turbine and auxiliaries
• Generator checks
• NDT on generator
• Radial alignment
• Axial alignment
• Clearances measurement
• Coupling run out
NDT –Trubine And Auxiliaries

• Visual inspection
• Blue matching of valves
• DPT & MPI of components
• UT of bearings
Turbine & Auxiliaries Visual Inspection

• Turbine blades, De aerator perforated sheets, rotor alumina blast cleaning


• Shafts of CEP,BFP and vacuum pumps
• HRH & MS strainers
• Valves seating area
• Valves blue matching-Line contact to be ensured
Turbine & Auxiliaries DPT and MPI
• Shafts of CEP,BFP and Vacuum pumps
• MS & HRH strainer line weld joints, control fluid oil line weld joints, impulse line weld
joints
• TDBFP gear coupling , bearings babbit metal area.
• Stop valves & control valves components
• MPI of rotor & blades
Generator Checks
After rotor threading out-rotor
• N2 pressure test (leakage - Not more than 0.5 kg/sg.cm for 6 hrs)
• IR value of rotor
• RSO test of rotor ( sinusoidal wave form)
• Winding resistance
Stator
• Visual inspection of stator
• IR value of stator
• Wedge tightness , ELCID test and tan ∆
• Winding resistance
Generator Checks-NDT
• DPT of compressor blades
• UT & DPT of gen. retaining rings (ASTM A435)
• DPT of seal oil system weld joints
• Completion of protocol before rotor threading in.
• IR values of Gen. Bearings
Generator & Auxiliaries Checks

• Compressor Hub And Baffle Ring Carrier Radial & axial Clearances( min.1.8)
• Radial alignment of GEN-Exciter and correction
• Axial alignment & Exciter Swing check
• CRO readings of gen. exciter
• Hydro test of H2 coolers and exciter coolers
• Gen. casing pressure test( 4 kg / sq.cm)
Other Areas

• DPT of expansion bellows


• DPT of HP heaters parting plane welds
• Condenser cleaning
• Deaerator visual inspection
• Drum internal inspection
THANK YOU
[email protected]

9346302240

You might also like