CONSEQUENCES OF BTL
FORCED SHUT DOWN OF UNIT UNWANTED GEN. LOSS AVAILABILITY LOSS INCREASE IN MAINTENANCE COST RELIABILITY HAMPERED PROFITABILITY LOSS .. AND SO MANY
FLUE GAS/ASH EROSION. OVERHEATING (LONG TERM/SHORT TERM). WELD JOINT FAILURE (SHOP / ERECTION / STUB). MAINTENANCE INDUCED DEFECTS. THERMAL FATIGUE (FIN / ATTACHMENT CRACK). CORROSION FATIGUE. STEAM EROSIN (SOOT BLOWER AREA)
NTPC LTD.
VINDHYACHAL SUPER THERMAL POWER STATION
LARGEST POWER PLANT OF INDIA TOTAL INSTALLED CAPACITY 3260MW STAGE I (6X210MW)-(1987 -91) STAGE II(2X500MW)-(1999-2000) STAGE III(2X500MW)-(2006-2007)
18 16 14 12 10 8 6 4 2 0
17
16
15 13
16
AIM: ZERO FORCED OUTAGE DUE TO BOILER TUBE LEAKAGE FROM OVERHAUL TO OVERHAUL.
IMPLEMENTATION OF RECOMMENDATION OF BTL ANALYSIS. IDENTIFICATION OF MAJOR EROSION PRONE AREA. PLANNED, ORGANIZED & THOROUGH INSPECTION AND COMPLETE BOILER MAPPING. AVAILABILITY OF QUALITY MATERIAL, TOOLS/ TACKLES, EQUIPMENTS, TRAINED /SKILLED MANPOWER & CONTRACT.
PROCESS CONTROL & STRINGENT QUALITY SURVELLIANCE DURING OVERHAUL. USE OF PROVEN NDT CHECKS AS WELL AS NEW TECHNIQUES FOR HEALTH ASSESSMENT & RLA STUDIES AS WELL AS FOR ASSURANCE OF QUALITY JOB DURING OVERHAUL.
TWO YEARS ADVANCE ROLLING PLAN FOR BOILER OVERHAUL & LINCENCE RENEWAL. WELL DEFINED ENGINEERING DECLERATION FOR THE WORKS TO BE CARRIED OUT WITH SPECIFIED TIME FRAME. AVAILABILITY / ADVANCE PROCUERMENT OF SPARES, MATERIAL TOOLS/ TACKLES & CONSUMABLES.
ALL PROCUREMENT VIA PRE DIFINED SPECIFICATION, QUALITY CHECKS AND THROUGH ESTABLISHED/ APPROVED VENDORS. AVALABILITY OF JOB CONTRACT IN ADVANCE. ALL CONTRACTUAL JOB SPECIFICATION AND SCOPE OF WORK WELL DEFINED AND TIED UP WITH STRINGENT QUALITYCHECKS/NORMS ON EACH STAGE OF WORK.
OVERHAUL
QUALITY OVERHAUL
PRE OVERHAUL QUALITY CHECKS FOR TOOLS/ TACKLES,CONSUMABLE MANPOWER & PROCEDURE
1.SKY CLIMBERS HEALTHINESS/ SCAFFOLDING MATERIAL SAFETY. 2. HAND TOOLS AND WELDING MACHINES 3.CRANES,HANDELLING EQUIPMENT,WINCHES. 4.POWER POINT HEALTHINESS (INCLUDING TEMPORARY LIGHTING)
5. CONTRACTORS STORE AUDIT FOR ELECTRODES,GAS AND OVEN CHECKING. 6. AVALIBILITY OF W.P.S. & P.Q.R. FOR DIFFERENT WELDING PROCESS INVOLVED IN PRESSURE PARTS. 7. WELDERS QUALIFICATION(H.P. AND L.P.)AND ISSUANCE OF WELDER IDENTITY CARD INDICATING HIS QUALIFICATION CRITEREA. 8. ENSURE COMPLET MOBILISATION OF BOILER PRESSURE PARTS CONTRACTOR AS WELLAS NDT CONTRACTOR . 9. COMPETENCE & ADEQUECY OF MANPOWER ENGAGED IN O/H TO BE ENSURED.
QUICK ERECT SCAFFOLDING IN 1ST PASS & 2ND PASS OF BOILER PR. PARTS AND UPTO ROOF FOR PENDENT COILS INPECTION. COMPLETE WASHING/ CLEANING OF BOILER FURNACE/ PENT HOUSE, GOOSE NECK. PROPER BUFFING OF BOILER TUBES & COMPLETE ILLUMINATION INSIDE OF BOILER.
THOROUGH VISUAL / PHYSICAL INSPECTION AS WELL AS D-METERING OF BOILER 1ST AND 2ND PASS EROSION PRONE AREA. BOILER TUBE THICKNESS MEASUREMENT (25000 READING IN 210 MW UNITS & 50000 READINGS IN 500 MW UNITS).
AREA OF D-METERING ECONOMISER COILS (U.B. & L.B.) UPTO HEADER BENDS. WATER WALL S-PANEL (FRONT/REAR) IN SIX STEPS UPTO NOSE BENDS. SOOT BLOWER AREA WW TUBES. BURNER BLOCK AREA GOOSE NECK BENDS. SCW TUBES OF ALL FOUR WALLS OF 2ND PASS IN LTSH/ RH REGULATING STAGE/ ECO AREA. HANGER TUBES.
R.H BENDS INSPECTION AFTER THE REMOVAL OF T BARS. LTSH COIL & ITS TERMINAL TUBE BENDS. DIVISIONAL PANEL, RADIANT S.H.,PLATEN S.H.(ALL MECHANICAL LOCKING AREA/ SPACER & BINDER TUBES AREA). SCREEN TUBES.
IDENTIFICATION AND PROPER MARKING OF ERODED TUBE FOR CUTTING. COMPLETE BOILER MAPPING. VISUAL INSPECTION OF REFRACTORY/INSULATION INSPECTION OF CASETTE BAFFLES,BINDERS TUBE COIL SUPPORTS AND SHIELDING, CLEARENCES &CHECK OF THE BENDS.
QUALITY INSPECTION BY SEPARATE GROUP FOR Ist & IInd PASS CONSISTING OF BMD+FQA PERSONNEL.
CORRECT PROCEDURE OF WELDING AS PER ESTABLISED W.P.S. & PQR. 100% RT OF ALL NEWLY WELDED JOINTS. PWHT AS PER APPROVED PROCEDURE, WHENEVER REQUIRED. WELDERS PERFORMANCES TO BE MONITORED ON DAILY BASIS & PROMPT CORRECTIVE ACTIONS TO BE TAKEN. ROUND THE CLOCK SURVELLIANCE DURING WELDING & RADIOGRAPHY.
IDENTIFICATION OF OVERHEATED TUBES. OXIDE SCALE MEASUREMENT FOR R.H.,S.H. COILS & OVERHEATED TUBE REPLACEMENT. HARDNESS SURVEY. SAMPLING FROM ALL THE HIGH TEMPRETURE ZONE FOR NECESSARY MICRO STRUCTURE ANALYSIS.
DOWNCOMERS & HEADERS CRITICAL WELD JOINTS & DMW JOINTS HEALTH ASSESSMENT & RLA IN PHASED MANNER ( FOR UNITS CLOCKING MORE THAN 1LAKH HRS.)
D.P.T. OF ATTACHMENT WELDS & DISSIMILER JOINTS: LIKE SCW HEADERS, RING HEADERS,HANGER SUPPORT OF PENT HOUSE, SPRAY LINE STUBS & OTHER CRITICAL STUB JOINTS, NIPPLE, GAMMA PLUGS & HAND HOLE WELDS,BOILER DRUM STEAM CHEST
CREEP MEASUREMENT OF HIGH TEMP. /PRESSURE LINES ON PREDETERMINED LOCATION AND COMPARISION WITH ORIGINAL VALUE. CHECKING OF HANGERS/SUPPORT & RESET IF REQUIRED. (HOT & COLD CONDITION READING TO BE USED FOR REFERENCE.) DRUM INTERNAL INSPECTION, PHYSICAL CONDITION OF DEPOSITS,PITTING,DAMAGE TO SURFACE, GENERAL CLEANLINESS ,CHECK FOR CHOCKING OF LINES & ANALYSIS OF DEPOSIT. DRAINS, VENTS, SPRAY LINES,VALVES INSPECTION & RECTIFICATION OF PROBLEMS.
DISADVANTAGE
MAJOR TIME CONSUMING WORK SPACE CONSTRAINT & DIFFICULT WORK ENVIRONMENT(AS COIL REPAIR IN THE AREA BETWEEN U.B. & L.B.) LIMITED NO. OF COILS CAN BE LOWERED AT A TIME. ALIGNMENT PROBLEM LEADING TO FURTHER EROSION IN 6 TO 8 MONTH PERIOD.
NEW STRATEGY
180 COIL TAKEN OUT & REPLACEMENT WITH PREFABRICATED & RADIOGRAPHED COIL. (ALREADY FABRICATED BETWEEN TWO O/H PERIODS)
OLD ERECTION/SHOP JOINTS RADIOGRAPHY AT APPROCHABLE LOCATION IN PHASED MANNER ( MAINLY FOR 500MW UNIT) STAGE I REGULATING COIL REVIVAL & COMPLETE INSPECTION FOR BEND EROSION. PROPER SHIELDING OF TUBES PRONE TO FLUE GAS EROSION. HYDRO TEST AS PER IBR NORMS & THEN FLUSHING THROUGH RING HEADER FOR REMOVAL OF FOREIGN MATERIAL
R.H. LEAKAGE CHECKING BY AIR PRESSURISATION RATHER THEN VACUUM PULING. ALL FINS WELDING DONE BY TESTED WELDERS. VISUAL INSPECTION & RANDOM DPT TO ENSURE QUALITY. ON LINE AVAILABILITY OF BOILER MAPPING & RADIOGRAPHY RECORDS. WELDING PROCESS STRINGENT CONTROL & TARGET FOR REPAIR RATE REDUCTION LESS THEN 3% FOR NEWLY WELDED JOINTS.
AUDIT OF BOILER OVERHAUL BY KNOWELDGE TEAM. SHARINGS OF THE LEARNINGS ACROSS THE PROJECTS.
IMPLEMENTATION OF NEW TECHNIQUE & RECOMMENDATION.
FIELD QUALITY
ASSURENCE
FQA SET UP
HEAD FQA REPORTING TO HOP AS WELL AS TO CQA. TRAINED EXECUTIVES OF ALL THREE DISCIPLINES i.e. CIVIL, MECHANICAL & ELECTRICAL. LAB ASSISTANT & TRAINED NDT STAFF MINIMUM LEVEL II TO SUPPORT THE SYSTEM. WELL EQUIPPED LABORATORY AND CALIBRATED TESTING EQUIPMENTS ALONG WITH NDT FACILITIES FOR CARRYING OUT VARIOUS TESTS AND CHECKS. SKILL UPDATION OF THE TECHNICAL STAFF ON REGULAR BASIS. AVAILABILITY OF STANDARDS, CODES, TECHNICAL SPECIFICATION.
ROLE OF FQA IN O&M PHASE OF POWER PLANT TIE UP OF QUALITY REQUIREMENTS FOR THE PROCUREMENT OF O&M SPARES DURING INDENT STAGE ITSELF. ENFORCING PDI CLAUSE FOR CRITICAL O&M SPARES. PREPARATION / APPROVAL OF MQP FOR SITE AWARDED INDENTS / P.O. VENDOR AUDIT AND STANDARDISATION. TECHNICAL SUPPORT IN SPARE PART DEVELOPMENT.
INVOLVEMENT IN FORCED OUTAGES, SHORT SHUTDOWN AND OVERHAUL. MONTHLY FEEDBACK ON QA ACTIVITIES TO HOP & CQA. MONTHLY QUALITY CERTIFICATION FOR O&M CONTRACTS PROGRESSIVE PAYMENT.
CO-ORDINATION WITH RIO FOR FACILITATING THE SPARES INSPECTION. RECEIPT INSPECTION OF SPARES AT STORES. QUALITY AUDIT ON PRESERVATION OF CRITICAL SPARES. PREPARATION / APPROVAL OF FQP FOR SITE AWARDED CONTRACTS. FINALIZATION OF MAINTENANCE QUALITY PLANS. ASSOCIATION WITH O&M IN WITNESSING CRITICAL CHECKS AND SURVEILLANCE ON MAJOR CHECKS
ORGANISATIONAL CHART
ED (ENGG.)
ED (REGION)
GM (CQA)
GM (ENGG.)
ED (STATION)
(AGM ) CQA
(AGM/DGM) RIO
(DGM ) FQA
Exec. (Elect.)
2nos.(O&M/Project)
5.
6. 7. 8. 9. 10. 11. 12.
13.
14.
RADIO ISOTOPES WITH TELEFLEX CAMERA. MPI KIT 2NOS. (1.MORE THAN 40,000AMP. 2. UPTO 20,000 AMP.) UT MACHINES -2NOS. D-METER WITH DATALOGGER -5NOS. D-METER -10NOS. IN-SITU METALLOGRAPHY KIT. HARDNESS TESTER (EQUO TIP -01NO. & CHINESE 01NO.) X-RAY M/C FOR ALUMINIUM WELDING EXAMINATION -01NO. UTM 60 TON CAPACITY 01NO. IMPACT TESTING MAQCHINE. PAINT THICKNESS ALCOMETER. OXIDE SCALE THICKNESS GAUGE. MATERIAL SORTER. VIDEOSCOPE.
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