Event Ana U#6-2006

EVENT ANALYSIS
UNIT NO: 6
Event no: 11/2006
Date: 01/12/06
Time: 07:02 hrs.
Load: 460 MW
Coal cycle in service: AB, CD, GH
Oil Support: NIL
Description: 1) Platen Superheater metal temp. high indication appeared @ 5:47 hr.
2) Abnormal sound noticed at RHS at Boiler near Platen Superheater zone.
3) Unit hand tripped @ 07:02 hr.
Window Indication appeared / Relay operated:
Trip fluid press very low Gen 6 lock out relay 2X/32G operated, Boiler Fire off, Turbine
Trip gear 10R2 operated. Unit switchgear 6A board auto changeover fails.
Boiler Light up:
Time02:00 Hrs
Date03/12 /2006
TG set synchronisation: Time09:37 Hrs
Date 03/12/2006
Problem faced during bringing back the set on bar:

1) Air flow to WB ( R ) was not showing hence Boiler tripped during purging @ 22:33 hr & 23:57 hr.
2) Oil gun AB2 & CD4 heavy leakage, CD3 gun choke up & jam.
3) Vacuum pump A, Air v/v not getting open, C/M 6B-seal Air v/v problem.
Analysis: Boiler tube leakage in Platen Superheater coil no.21 & spacer tube.
Work Carried Out: 1) BM-II section: i)Defective steam cooled spacer tube and tube no.1&2 of coil no. 21
replaced.
ii)Male female connector weld to S.C. spacer tube. out.
2) I&C-II section: Secondary Air flow (RHS) positive press impulse line was sheared off from Aerofoil (near
duct).
3) TM-II section: No work carried out.
4) EM-II section: No work carried.
Recommendations:
Short Term: Failed tubes replaced by new one.
Long Term: 1) Complete steam cooled spacer tube will be replaced during off.
2) Male female connectors will be procured from BHEL only to ensure quality of material.
Remark:
GM-II:
POG/VARIOUS REPORT/EVENT ANALYSIS
EVENT ANALYSIS
UNIT NO: 6
Event no: M19/2006
Date: 11/10/06
Time: 05:20 hrs.
Load:
Coal cycle in service:
Oil Support: NIL
Description: 1) 05:20 hr abnormal sound heard in BSDP4 pump & series stopped immediately.
2) 09:00 hr series started after checking freeness of BSDP4 pump by B/M for trial during
stopping the series, metallic sound heard in pump.
N/A
Boiler Light up:
Time
Hrs
Date /2006
TG set synchronisation: Time
Hrs
Date /2006
N/A
Analysis: After inspection of pump, impeller found broken.

Work Carried Out: 1) BM-II section: After inspection on 16/10/2006, impeller, inner casing were found
damaged and suction cover was already leaking. Due to non-availability of spares impeller inner casing and
suction cover assembly were taken on 16/10/06 at 19:00 and the pump was found normal.
2) EM-II section: No work carried out.
4) TEST-II section: No work carried out.
Recommendations:
Short Term: To avoid chocking of live, flushing is to be carried out with sufficient fly ash.(This fly ash is not
getting now-a-days). Also monitor the current of series.
Long Term: Due to increase in frequency of bottom ash evacuation, pump spares to be replaced after 3500 to
4000 hrs. for replacement stock of spares to be maintained. Hence the procurement of spares to be carried out
in time. Also to avoid failure of spares at early stage quality of spares particularly Impellers & Inner casing
are required of good quality to give the required life, which is not observed in last 2 to 3 years.
Remark: Matter is taken up with OEM.
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: M18/2006
Date: 30/08/2006
Time: 13:05 hrs.
Load: 470 MW
Coal cycle in service: six
Oil Support: NIL
Description: Current of B series shot upto 75 Amp from 46 Amp. Series Immediately stopped. Old patch get
opened near Delcon Gate. Prior to that i.e. at 12:00 hrs current were 46/46/40/38 and B/A was just completed
and Fly ash evacuation was in progress. At 11:45 hrs BM staff on patrolling reported that discharge was 80%.
ASDL-6B choke-up.
NA
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
NA
Analysis: Series current from morning were as under08:00 hrs
52/52/48/44
09:00 hrs
50/50/46/44
(07:45 to 08:45) B/A
10:00 hrs
50/50/46/44
(08:45 to 10:45) F/A
11:00 hrs
50/50/46/44
12:00 hrs
46/46/40/38
(10:45 to 12:00) B/A
13:00 hrs
46/46/40/38
(12:00)
F/A started.
There was no indication of line c/v after 1 st B/A evacuation. Currents dropped after 2 nd B/A evacuation
so line was Kepton flushing by F/A.
Work Carried Out: 1) BM-II section: Discharge checked at 10:30 hrs observed 80%. It was reported in
section at 11:40 hrs. Line choke-up removed by patch cutting from C.P. no 21 to 363 afterward line was
observed empty. Line broken at C.P. no-38, pipe replaced.
4) TEST-II section: No problem.
Recommendations:
Short Term: During evacuation, current of pumps if observed on lower side i.e. below 46 Amp. Then stop the
evacuation immediately and carry out flushing by F/A or water to improve pumps currents trip to normal to
avoid choke-up.
Long Term: Work order is placed for replacement of worn out pipes. Broken pipe at C.P.no-38 was dui
for replacement. Now these pipes will be replaced in the month of Sept.06 by new pipes available with BM-II
section.
Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: M17/2006
Date: 01/08/2006
Time: 11:00 hrs.
Load: 460 MW
Coal cycle in service: AB, CE, GH
Oil Support: NIL
Description: SF6 Gas press at dial gauge of breaker-UAT 6D to 6D bus was showing very low but lamp
indication & annunciation window not appeared.
N/A
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
NIL
Analysis: As precautionary measure, load reduced from 460MW to 360 MW, Coal Mill H withdrawn, loading
of PA Fan 6B & ID Fan 6C & 6D made minimum.
11:18 hrs 6D board changeover from UAT to station by fast transfer scheme, Annunciation circuit checked by
testing after replacement of breaker. After taking clearance from LD, station to UAT 6D changeover at 23:35
hr of 6D bus incomer.
Work Carried Out: 1) TEST-II section: The relay healthiness (74 B) and annunciator circuit checked, found
OK, however, wiring in the (male/female) plug found wrongly corrected. The same made normal & trial taken
found OK.
4) BM-II section: No work carried out.
Recommendations:
Short Term: All pressure switch contacts of SF-6 ABB make shall be checked and corrected in coming
Annual O/H of U#6.
Long Term: During Annual / Capital overhaul of the Units all pressure gauge of SF-6 breakers shall be
checked for healthiness and corrective action shall be taken if any abnormality is observed.
Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: 10/2006
Date: 28/07/2006
Time: 23:05
hrs.
Load: 340
Coal cycle in service: AB, CD
Oil Support: NIL
Description: T.A. set hand tripped for attending GTR R, PRV wire earthing is to be removed & main
Turbine Governing oil filters at Governing rack-cleaning work.
Window Indication appeared / Relay operated: Turbine-Hand tripped & Boiler-withdrawn.
Boiler Light up:
Time04: 35
Hrs
Date29/07 /2006
TG set synchronisation: Time07: 10
Hrs
Date29/07 /2006

1) Main turbine over speed device filter flange joint leakage.
2) Main Turbine DC AOP feeder one fuse base burnt.
3) Breaker Trolley of TD BFP 6B is utilized for DC AOP of Main Turbine.
Analysis: GTR R PRV cable earthing removed & PRV trip protection put into service.
Work Carried Out: 1) TM-II section: Governing rack online filter cleaned. MOT oil topped up. Main
turbine over speed trip device on line filter flange leakages, bolts tightening done. By mistake while attending
oil leakage from over speed device flange heavy leakage, due care should be taken who are attending such
leakage.
2) TEST-II section: T.B. on PRV cleared and healthy core of the cable connected to the trip contact.
3) EM-II section: PRV JB is covered with polythene paper & plastic bucket coated.
4) I&C-II section: No work carried out.
Recommendations:
Short Term: PRV cable from PRV to JB shall be replaced by new cable during coming Annual Overhaul.
Long Term: -Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: M16/2006
Date: 26/07/2006
Time: 04:20 hrs.
Load: 470 MW
Coal cycle in service: ABCEFG
Oil Support: NIL
Description: 1) 04:20 hrs: a) GT-6 Bay breaker trip circuit trouble.

b) GT-6 Bay breaker Air Gas press lock out indications appeared on COD-8.
2) 05:15 hr: NIT contact multiplier supply fail indication appeared.
Window Indication appeared / Relay operated:1) GT-6 Bay breaker trip circuit trouble.
2) GT-6 Bay breaker Air Gas press lock out.
3) NIT contact multiplier supply fail.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
Problem faced during bringing back the set on bar
N/A
Analysis: Informed to GCR & testing staff (Gen). In presence of testing staff at 06:40 hrs, Unit-6 load
transferred from main breaker to transfer breaker to attend the trouble of main breaker at GCR.
Work Carried Out: 1) TEST-II section: GCB gas/air pressure lockout annunciator appeared in PCR due to
faulty contact of DC changeover relay same was replaced by GCR staff. After clearance from GCR staff, U6
load again transferred on main breaker.
Recommendations:
Short Term: -Long Term: -Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: M15/2006
Date: 20/07/2006
Time: 09:15 hrs
Load: 488 MW
Coal cycle in service: six
Oil Support: Nil
Description: All running Service/Instrument air compressor got unloaded

Window Indication appeared / Relay operated: Instrument/Service air pressure low indication appeared on
COP.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
N/A
Analysis: Control supply MCB found tripped.

Work Carried Out: 1) TEST-II section: Existing MCB suspects faulty and same will be replaced & auto
changeover trials of control supply will be taken during shutdown of the unit.
Recommendations:
Short Term:
Long Term:
Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: 09/2006
Date: 16/07/2006
Time: 23:23 hrs.
Load: 400 MW
Coal cycle in service: AB, DE, GH
Oil Support: NIL
Description: Unit was withdrawn to attend CRH spray line NRV (RHS) and FRF bucket filter cleaning work.
Window Indication appeared / Relay operated: a) Control room emergency trip operated.
b) GT-6 lock out (Gen. Protection) relay operated.
c) Trip fluid pressure very low.
d) Condenser pressure very high.
e) Boiler fire off.
f) Turbine trip gear operated.
Boiler Light up:
Time05:16 Hrs
Date 17/07/2006
Date 17/07/2006
N/A
Analysis:
I) CRH spray line NRV (RHS) replaced by valve from Unit-5 boiler.
II) FRF bucket filter cleaned.
Work Carried Out: 1) I&C-II section: No work carried out.

Recommendations:
Short Term: RH spray line NRV from Unit-5 boiler removed & welded in Unit-6 boiler.
Long Term: Welded valve will be replaced by new valve (Auto make) during AOH in Aug-06.
Remark:
GM-II:
EVENT ANALYSIS
UNIT NO: 6
Event no: 08/2006
Date: 13/07/2006
Time: 00:03
Load: 430 MW
Coal cycle in service: AB, CD, FG
Oil Support: NIL
Description: Due to flash over occurred on EMPA sec-II in TDBFP-6A, AOP-II feeder. All SAH tripped
consequently boiler tripped on all SAH off protection.
Window Indication appeared / Relay operated: 1) Gen.lock out relay.
2) G.T.marshalling box supply fail.
3) Master fuel relay trip operated.
4) 220V D.C. battery charger trouble.
5) Gen. H2 concentration low.
6) Boiler fire off.
7) Condenser pressure value high.
8) 24V battery charger- II trouble.
Boiler Light up:
Time01: 50 Hrs
Date 13/07/2006
Date 13/07/2006

1) L.P. heater no.2 C.D.-40 valve jam.
2) T.A. set tripped on turbine on turbine HPT exhaust temp. high. a) 3000 rpm. at 04:22 hrs.
3) Oil gun AB 1 & 3 did not prove. Also CD elevation no.1 not proved.
Analysis: Flashover occurred in breaker trolley of AOP-II of TDBFP-6A. When AOP was running on EMPA
sect-II became dead on. Instantaneous over current RELAY operation and both SAH 6A/6B standby motor
tripped, boiler tripped on interlock.
Work Carried Out: 1) EM section: Burnt breaker Trolley of TD BFP-6A: AOP-II is replaced by Trolley of
TD BFP-5A: AOP-II. The same shall be put in Unit-5.
2) Test-II: After putting Trolley from Unit-5, Boiler ON/OFF and protection tripping trail on thermal
overload taken & found OK. LT make SPPR & thermal overload being procured and will be replaced after
procurement.
3) TM Section: No work carried out.
4) BM Section: No work carried out.
5) I & C Section: No work carried out.
10
Recommendations:
Short Term: Preventive maintenance of motors, LT motor breaker Trolley shall be tightened. Incoming /
outgoing female contact shall be checked for the healthiness.
Long Term: During annual overhauling of Unit the extensive preventive maint. of LT switch gear shall be
carried out , bus connections shall be ensured for tightness and abnormality observation shall be attended.
Remark:
GM-II:
11
EVENT ANALYSIS
UNIT NO: 06
Event no: M14/2006
Date: 03/07/2006
Time: 13:00
Load: 425 MW
Coal cycle in service: B, C, D, E, F, H
Oil Support: NIL
Description: U5 DG set load trial taken from 11:05 to 12:05 hrs after normalization relay temp. started
dropping and started rising again & shut up to 30.60 0C.
2) Window Indication appeared / Relay operated: PCR AC compressor no.3 tripped.
Boiler Light up:
Time
Hrs
Date
Hrs
Date
NA
Analysis: Compressor tripped on chiller water temp. low. On checking main damper found closed,same
opened electrically.. Initially damper was opened, otherwise AHU remained running. After closing of damper,
AHU should have tripped.
Work Carried Out: 1) Test-II section: Take the trails by opening fire damper, then motorized dampers,
AHU & then starting the compressor and raised the defect to the concerned comprehensive maintenance.
2) TM-II section: Fire damper opened & compressor cut in service.
4) EM section: No work carried out.
5) I&C section: No work carried out.
Recommendations:
GM-II:
12
EVENT ANALYSIS
UNIT NO: 6
Event no: M13/2006
Date: 30/06/2006
Time: 00:00
Load: 465 MW
Coal cycle in service: AB, CD,EG
Oil Support: NIL
Description: AC plant (PCR) compressor no-3 tripped. OPB board section-2 found tripped. Bus coupler did
not get ON on auto causing tripping of PCR AC plant board.
Window Indication appeared / Relay operated: PCR AC compressor-3 off. 63 CD relay on SF12/2-2 stn
stgr OPB section. If Incomer-2 trip and stn swgr OPB auto changeover fail indications on WP 18 did not
appear.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006

If Incomer got ON but tripped as soon as switch put on remote, so charged thro buscoupler. But AHU were
not getting ON FD(fire damper) on command given to all six dampers & BC resetted AHU got ON.
Analysis: Water particle appeared is suspects from condensation of moisture in air (Humidity > 70%). So AC
duct damper above cup 18 closes.
Work Carried Out:
1) Test-II section: a) OPB Tr. OXD No (sect-II) in PCR cup 18 panel water
condensation found in TB/JB resulting tripping of LT incomer.

b) Bus coupler auto pick up contact is also in same JB, which has not resulted into closing breaker on auto.
c) Remote tripping switch shall be replaced in available S/D JBs/TBs dryed by EM-II taken in auto service.
2) EM-II section: JB & TB dryed.
Recommendations:
Short Term:
Long Term:
Remark:
GM-II:
13
EVENT ANALYSIS
UNIT NO: 6
Event no: M12/2006
Date: 24/06/2006
Time: 02:20
Load: 380 MW
Coal cycle in service: AB, CE, GH
Oil Support: NIL
Description: Coal Mill-6C tripped without any indication. At boiler desk Lub system permit disappeared.
Lub pump ON,& Lub pump trip both indications persist.
Window Indication appeared / Relay operated: Coal Mill tripped.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
Problem faced during bringing back the set on bar: Lub oil pump manually made off from local & started
LOP trip indication resetted and Lub system permit disappeared at desk permissive to C/M 6C for starting.
Lub oil pressure drop below 1.5 kg/cm2 .
Analysis:
Work Carried Out: 1) EM section: No work carried out.
2) Test-II section: No work carried out.
4)TM-II section: No work carried out.
Recommendations:
Short Term: During A type maintenance of coal mill i.e. above 500 running hours, we have cleaned the lub
oil filters to avoid the low oil flow to gear box bearings.
Long Term: --Remark:
GM-II:
14
EVENT ANALYSIS
UNIT NO: 6
Event no: M11/2006
Date: 11/06/2006
Time: 23:40
Load: 500 MW
Coal cycle in service: AB,DE,FH
Oil Support: NIL
Description: CCW 6B motor tripped on differential Protection and 6 CWXA transformer tripped, as a result
of which ACW 6A, CCWP-6A tripped. Load reduced to 350 MW. The Master-tripping relay of transformer 6
CWXA resetted. Supply to section-II normalized. The CCW/ACW pumps started and load normalized.
Window Indication appeared / Relay operated: CCW-6B-87 M-motor Diff relay.
6 CWXA transformer: a) 86- Master tripping relay.
b) 2.7- Instrument v/voltage relay.
c) 2.27- Time delay v/voltage relay.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
N/A
Analysis: The tripping of 6 CW6A transformer, without any specific indication, may please be checked.
Work Carried Out: 1) EM-II section: Replaced both lugs and terminal bushings.(lugs used 240 copper.
2) Test-II section: CCW transformer 6A tripped on LV REF protection which flag was found partially
operated. Servicing of the same will be done during shut down.
Recommendations:
GM-II:
15
EVENT ANALYSIS
UNIT NO:6
Event no: 07/2006
Date: 08/06/2006
Time: 23:14
Load: 385 MW
Coal cycle in service: ACDEG
Oil Support: NIL
Description: D.M. makeup shoot up to 90 T/hr hence boiler is inspected. Abnormal sound observed at 54 m
(U7 side), turbine hand tripped and boiler withdrawn due to Wall Reheater tube leakage.
NIL
Boiler Light up:
Time 01:50Hrs
Date10/06/2006
TG set synchronisation: Time 08:00Hrs
Date 10/06/2006

1) Boiler tripped due to loss of fuel at 02:26 hr, as coal feeder C started from local by BM.
2) Boiler light up at 02:40 hrs.
3) DC scanner fan did not peaked up on auto.
4) Gate wall gearing did not close on auto.
Analysis: Reheater waterwall tube no-3 (near divisional Panel No-1) pin hole near clit.
Work Carried Out: 1) BM section: Stainless steel shielding fitted on eroded tube.
2) EM section: UAT-6A: oil lkg from Y- LV bushing attended.
Recommendations:
Short Term: 1)UAT-6 O/H shall be done during Annual overhaul. During the O/H works, gaskets/oilseals
shall also be replaced.
2) Metal deposition done on leaky tube after grinding.
3) New clit welded properly between tube no 1&2.
Long Term: 1) UAT-6A O/H & internal inspection shall be carried out after every 7-10 years of continous
service.
2) Attachment welding shall be done with full fillet.
Remark:
GM-II:
16
EVENT ANALYSIS
UNIT NO: 6
Event no: 06/2006
Date: 06/06/2006
Time: 16:57
Load: 495 MW
Coal cycle in service: AB, CD, EG
Oil Support: NIL
Description: M/7881 applied by TM-II for connecting TDBFP 6A CRH line to condenser to attend safety v/v
leakage, for that HP flash box stand pipe middle v/v and CRH line v/v and safety v/v required to be opened
keeping watch on vacuum. So fire HP flash box v/v opened, no drop in vacuum observed. Then CRH line
drain opened. CEP tripped on hotwell level very low (actual level was normal)
Tripping both BFPs on quenching pressure low and boiler tripped on All BFPs OFF and TA set on interlock.
All ID fans also tripped, tripping both FD fans. No indication on bkr/PCRBoard c/o was OK.
Window Indication appeared / Relay operated: All BFPs OFF; Master fuel trip; All ID fans trip; both FD
fans trip.
Boiler Light up:
Time 17:23Hrs
Date 06/06/2006
Date 06/06/2006
NIL
Analysis: TDBFP CRH line was actually connected to Hotwell standpipe.Hotwell, very low level switches
operates due to this operation. All ID fans tripped on furnace pressure very low but this is possible only if FD
fans tripped first but as per SOE ID fans tripped and FD fans trip time is same.
Work Carried Out: 1) EM section: No work carried out.
3) TM-II section: CRH drain of TDBFP was disconnected standpipe of condenser.
4) I&C-II section: 1) CEP protection is provided through Hotwell level very low 2/3 switches
operation.2Nos. of switches are installed on U5 side standpipe and 1No. switch is installed on U7 side
standpipe.
17
As CRH drain of TDBFP6A is directly connected to U5 side standpipe to attend TDBFP6A safety
Valve leakage, water inside standpipe got evacuated to condenser, both level switches got operated and 2/3
protections acted. ALL running BFPs tripped on CI seal quench differential pressure very low interlock.
Boiler tripped on all BFPs off and turbine tripped on Boiler trip instantaneously.
2) Running ID&FD fans tripped on post purge fan trip interlock from FSSS as per logic.
5) BM section: No work carried out.
Recommendations:
Short Term:
Long Term:
Remark:
GM-II:
18
EVENT ANALYSIS
UNIT NO: 6
Event no: 05/2006
Date: 25/05/2006
Time: 02:40
Load: 470 MW
Coal cycle in service: AB, CD, FH
Oil Support: NIL
Description: Furnace Draft was unstable, ID margin was 100%, DM make-up 100%, boiler is checked and
abnormal sound is observed at 63m at U5 side (near LRSB).TA set is w/d.
Window Indication appeared / Relay operated: Boiler / Turbine w/d.
Boiler Light up:
Time 11:52Hrs
Date 28/05/2006
Date 28/05/2006

1) Boiler light up delayed, as MFT was not resetting after purge complete.
2) Due to passing of AS10 & AS12 v/v, gland seal pressure was inadequate, AS4 v/v was 10% open,
same closed.
Analysis: R/H coil no 43, T6 burst opened (thick lip) due to overheating (primary failure). Coil no 42-T3, T4,
T5, T6, T7 & T8-burst opened. Coil no 44-T4, 5,6,7&9 dislocated. T8-Erosion. Coil no 45-T6, 7-puncture.
Total joints-71.
Work Carried Out: 1) BM-II section:
a) Coil No 42-Tube No.3to7 replaced.
b) Coil No 43-Tube No.4to8replaced.
c) Coil No 44-Tube No.4to7,8 replaced.
d) Coil No 45-Tube No.4, 6,7 replaced.
e) Coil No 46-Tube No.1 replaced.
Total joints=71.
2) I&C-II section: Boiler light up delayed by only 5-10 min. This is attended after checking redundant trip
ckt of FSSS panel.
3) EM section: No work carried out.
4) TM section: No work carried out.
5) TEST section: No work carried out.
Recommendations:
Short Term: a) In-situ oxide scale thickness measurement will be carried out during OH in Aug-06.
b) As per the preliminary report and visual inspection overheated tubes will be replaced during Oh in Aug-06.
Long Term: Coil No 38 to 46 will be replaced during OH in Aug-2007 with the upgraded material.
Remark:
GM-II:
19
EVENT ANALYSIS
UNIT NO: 6
Event no: M10/2006
Date: 03/05/2006
Time: 13:57
Load: 500 MW
Coal cycle in service: AB, CD, FG
Oil Support: NIL
Description: TD BFP-6A got unloaded, immediately MD BFP-6D taken on load and drum level normalized.
Window Indication appeared / Relay operated: Drum level low indication appeared in COD.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006

Analysis: From HSR it is seen that prior to unloading of pump even though governing oil pressure is normal
i.e. 8.0 kg/cm2, there is slight dip in oil pressure to main governing v/v and EHG position.
Work Carried Out: 1) I&C-II section: EHG position suddenly dropped by around 2% without reduction in
main Sec. Oil pressure as is evident from the enclosed bend. This happened may be either due to spool
malfunction and EHG feedback ckt problem. EHG feedback transmitter replaced by new one and calibration
is done. Governing characteristic taken from MCV & ACV opening. TDBFP-6A put on EHG on
Dt:04/05/2006 at 14:00 hrs and is running normal till date.
2) TM-II section: EHG spool cleaned in co-ordination with I&C.
Recommendations:
Short Term: I&C-II carried out the work in co-ordination with TM-II on 11/06/2006 and 15/06/2006.
Long Term: -Remark:
GM-II:
20
EVENT ANALYSIS
UNIT NO: 6
Event no: M9/2006
Date: 02/05/2006
Time: 15:00
Load: 500 MW
Coal cycle in service: AB, CD, EF
Oil Support: NIL
Description: LHS RH spray line between R19 & R10 v/v punctured. Spray control v/v opening requirement
increased beyond 100% at 15:00 hrs. Unit load reduction started to achieve the condition for block v/v
closing.
---
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
Problem faced during bringing back the set on bar: RH spray block v/v at 16:26 hr at RH metal temp. 582 o
C. Block v/v opened at 16:36 hr at RH metal temp 614o C after the clamp fixing on pipeline.
Unit put on CMC at 18:00 hr at 490 MW. RH spray control v/v opening reduced up to 30%.
Analysis: RH spray line was eroded at the D/S of R19 v/v after welding joint. Exact pattern of erosion could
not be seen as clamping was done online. Erosion of pipe may be due to change of fluid path & subsequent
cavitations after welding joint.
Work Carried Out: 1) BM-II section: Damage pipe is replaced during s/d.
Recommendations:
Short Term: Leakage is attended by online sealing by fabricating suitable clamp.
Long Term: Size of existing pipe (60.3*6mm) replaced by new thick (60.3*8mm) pipe.
Remark:
GM-II:
21
EVENT ANALYSIS
UNIT NO: 6
Event no: M6/2006
Date: 01/05/2006
Time: 20:23 Hrs
Load: 500 MW
Coal cycle in service: AB, CD, FH
Oil Support: NIL
Description: TD BFP 6A tripped at 20:23:36 hrs on turbine Governing oil pressure very low. CMC w/d Unit
load reduced to 453 MW. RC valve of BFP-A open condition but showing discrepancy on control desk.
Window Indication appeared / Relay operated: --Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006

MD BFP picked-up on Auto. Flow established after 10 sec,meanwhile BFP D started and taken on load
manually. Drum level normalized. Unit put on CMC at 20:45 hrs with BFP B&D. MD BFP-6C kept on auto
S/D.
Analysis: --Work Carried Out: 1) I&C-II section: All 3 Gov. oil header pressure very low pressure switches calibrated
& reinstalled after impulse line flushing. Tripping signal on Gov. oil header preesure very low(2 out of 3)
actually tested by draining switches & found OK. TD BFP 6A RC v/v console module discrepancy got
resetted after acknowlegment.Clearance given for TD BFP 6A to take on load.
Recommendations:
Short Term:
Long Term:
Remark:
GM-II:
22
EVENT ANALYSIS
UNIT NO: 6
Event no: M5/2006
Date: 07/04/2006
Time: 15:05 Hrs
Load: 500 MW
Coal cycle in service: AB, DE, FH
Oil Support: NIL
Description: At 15:05 Hrs, FSSS supply fail, resulting seal air fan-6A and scanner fan-6A tripped. Standby
seal air fan-6B & scanner fan DC not pick-up.3 running c/c-BDH out of six c/c-tripped,on seal air not
adequate. No any oil e/v available, due to FSSS fail. Only c/c A,E,F was remain in service. Hence,load start
reducing from 500 MW to 300 MW.
Window Indication appeared / Relay operated: AC scanner fan-6A tripped indication on COD-1.
Seal air fan-6A tripped indication on CUP-2.
Seal air header pressure low indication on CUP-2.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006
NIL
Analysis: Checked by I&C-II and found FSSS unit control panel processor application s/w got erased.
Programme is reloaded and unit got normalized.
Work Carried Out: 1) I&C-II section: The failed FSSS processor is reloaded and system is normalized.
5) TEST-II section: No work carried out
Recommendations:
Short Term: Program is reloaded and system is normalized.
Long Term: The matter is being reffered to BHEL, Trichy.
Remark:
GM-II:
23
EVENT ANALYSIS
UNIT NO: 6
Event no:04/2006
Date: 19/03/2006
Time: 09:31 Hrs.
Load: 495 MW
Coal cycle in service: B, D, E
Oil Support: AB
Description: Abnormal sound heard near LRSB 107 DM makeup increased. Boiler w/d at 09:31 Hrs due to
Reheater Tube leakage.
Window Indication appeared / Relay operated: 1) Gen-6 lockout relay operated (86G1).
2) Gen-6 lockout 2*132G trouble.
3) Trip fluid pressure very low.
Boiler Light up:
Time 12:10Hrs
Date 21/03/2006
Date 21/03/2006

Boiler tripped at 15:10 Hr on air flow <3%. Airflow came down immediately & again became normal.
Relighted at 15:25 Hrs.
Analysis: Platen Reheater coil No 45-Tube No 15. Welding joint cracked T-16 erosion, T-14 Burst open, T-11
to 13 punctured, T-7 overheating.
Work Carried Out: 1) BM-II section: a)Attended the welding joint failure of tube and tube leakage.
5) TEST-II section: No work carried out
Recommendations:
Short Term: a) Radiography of welding joint whch were carried out in TP347H material before 2002(in coil
no 43 to 46) will be done during OH in Aug-2007.
b)Tube No 7,11,12,13,14 & 16 replaced by new tubes.
Long Term: Coil No 38 to 46 will be replaced during OH in Aug-2007.
Remark:
GM-II:
24
EVENT ANALYSIS
UNIT NO: 6
Event no: M4/2006
Date: 09/02/2006
Time: 16:40 Hrs.
Load: ON BARRING
Coal cycle in service: ---
Oil Support: NIL
Description: ST-4 tripped on B/B protection and all running Aux. Tripped. Unit-6 under S/D to attend Boiler
tube leakage. EMPA supply not restored from main/standby D.G. set.
Window Indication appeared / Relay operated: 1) ST-4 B/B protection trip.
2) ST-4 MB Aux. Supply fail.
3) SF 15,16,incomer breaker trip.
4) SF 11/1,11/2 incomer breaker trip.
5) SF 13,17 breaker trip.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006

D.G. set (Main) picked up on auto but its in breaker going to EMPA board not getting close. Hence EMPA
board not charged through D.G. set and all Aux. PWPB, AOP1, JOP1, ACSOP1.
Analysis: C/F pump and all oil pump tripped(ID fan, FD fan)Standby DG set not picked up due to smoke
observed from battery ( S/B DG set Battery lead burnt).
Work Carried Out: 1) EM-II section: Standby D.G. set battery (BB1) burnt leads replaced. Battery set cell
voltages / specific gravity and level checked and found normal except cell No.2 which showing Sp. Gravity at
1100.
2) TEST-II section: D.G. set (main) breaker did not close because of faulty test/remove set connector. Trail of
breaker taken and found OK.
5) TM-II section: No work carried out
Recommendations:
Short Term: Regular checking of DG battery set as per schedule i.e. cell voltage sp.gravity and water level
along with healthiness of connections/ lead shall be done.
Long Term: After every 2 years, the DG set batteries shall be replaced irrespective of healthiness.
Remark:
GM-II:
25
EVENT ANALYSIS
UNIT NO: 6
Event no:M3/2006
Date: 06/02/2006
Time: 11:00 Hrs.
Load: 500 MW
Coal cycle in service: ---
Oil Support: NIL
Description: 415V 6AHPA at AHP was independently charged from Incomer-I (6AHXA Xmer) and IncomerII (6AHXB Xmer). Incomer-II is attempted to make OFF in presence of EM-II & Test-II engg. I&C-II didnt
trip (Attended by Test-II& made OFF). Bus coupler did not get ON during the event control supply to slurry
disposal pump panel and auxiliary pump panel tripped resulting in tripping of HPSWP & LPSWP. However
running series pumps (B series) did not trip & made OFF manually. Bus coupler problem attended by Test-II
& board charged thro bus coupler.
Boiler Light up:
Time
Hrs
Date /2006
Hrs
Date /2006

Analysis: On tripping of L.P. seal water pump, seal water pressure becomes low. However due to failure of
control supply, timer of seal ater pressure low did not pick up. Hence series pump could not trip.
Work Carried Out: 1) TEST-II section: When AC control supply to slurry pump fails, a timer (5 sec.) is
energized & tripping is given to all running series pumps. Similar modification is already done in Unit-5.
5) BM-II section: No work carried out
Recommendations:
Short Term: --Long Term: --Remark:
GM-II:
26
EVENT ANALYSIS
UNIT NO: 6
Event no: 03/2006
Date: 08/02/2006
Time:
Load:
Coal cycle in service:
Oil Support: NIL
Description: T.A set w/d for Boiler Tube leakage in Platen Reheater outlet header at Pent House.
Window Indication appeared / Relay operated: Unit board 6A did not get charged over from UAT to
station.
Boiler Light up:
Time 05:45Hrs
Date 11/02/2006
Date 11/02/2006
NIL
Analysis: Tube leakages Status (Platen Reheater-Primary)

1) LTSH coil No-116, Tube No-7=2 No.of joint
2) Platen S/H Header coil No-16, Tube No-4&7=2 No joint (Tube)=2 No.of joints (Stub)
3) R/H coil No 45=31 No. of joints
Work Carried Out: 1) BM-II section: Eroded/punctured tubes replaced.
2) TEST-II section: Bus transfer scheme-6A check synchronization relay tested & found OK.6A-Tie breaker
open/close time measured found OK. (Bus transfer from Station to Unit & Unit to station taken) Also auto
changeover trial taken by operating Master trip relay (2*132G1) & found OK.
Recommendations:
Short Term: All eroded / punctured tubes replaced.
Long Term: 1) Heavy oxide scales observed in reheater outlet header tubes in coil No-41 to 46 shall be
replaced during OH in Aug-2006.
2) Failed tube sample & 1 unfailed tube sample with oxide scales is being sent to BHEL.
Remark:
GM-II:
27
EVENT ANALYSIS
UNIT NO: 6
Event no: 02/2006
Date: 13/01/2006
Time: 22:40
Load: 500 MW
Coal cycle in service: AC, DE, FG
Oil Support: NIL
Description: Set tripped on flame failure.

Window Indication appeared / Relay operated: SGC fault; New SGC fault, HP/IP trim device fault;
Turbine trip generator 1 or 2 operated. Boiler fire off; Gen-6 lock out relay 2X/32G operated; Gen-6 lock out
relay fault;Unit flame 1612 trip.
Boiler Light up:
Time 23:45Hrs
Date 13/01/2006
Date 14/01/2006

EF3 oil gun scanner was showing flame so purge ready, was not available. DC JOP was tripping within few
minutes due to timer contact problem.
Analysis: CCW pump house 11KV board section-II P.T. smoke observed. 6D board tripped. CCW section-II
did not tripped. P.A. board section-II became dead its bus coupler did not picked up.
Work Carried Out: 1) TEST-II section: DC JOP local Panel start circuit timer replaced. Trail OK.
3) I&C-II section: All panels holes, cable entry sealing checked found OK.
5) BM-II section: No work carried out
Recommendations:
Short Term: On 6D board Tie feeder of CCW-6D instantaneous over current relay provided trail taken found
O.K. In next available S/D timer will be provided on Tie feeder of CCW for proper gradiation. PA board auto
changeover trail should be taken in next S/D.
Long Term:
Remark:
GM-II:
28
EVENT ANALYSIS
UNIT NO: 6
Event no:01/2006
Date: 09/01/2006
Time: 16:50
Load: 350 MW
Coal cycle in service: A,B,C,E,F
Oil Support: NIL
Description: Boiler tripped on Furnace pressure very high at 16:50 Hr. Load was reduced from 500 MW
due to Clinker formation at 16:15 hrs.
Window Indication appeared / Relay operated: Master fuel trip, High Furnace pressure Fast transfer mode
6A not available cup-20 BCW pump-A tripped, CEP-A tripped, FD fan-A tripped.
Boiler Light up:
Time 17:03Hrs
Date 09/01/2006
Date 09/01/2006

1) MD BFP-C discharge pressure not increasing.
2) Ex-6: Deareator pegging v/v not opening by motor and also with manual.
3) Turbine lub oil temp control v/v sluggish.
4) LPBP v/v not getting open above 75%.
Analysis: Boiler peephole U7 side was found full of bottom ash, sudden fall of big clinker at 16:50 Hrs. All
Clinker grinders were not starting due to control supply failure.
Clinker on 1B & 2B ash gate removed.
Work Carried Out: 1) TEST-II section: 6A board changeover work/trail was taken during S/D. Also control
supply of clinker grinder circuit checked found no abnormality.
2) BM-II section: Partial Bottom ash removed by ground unloading & remaining removed through system
after making grinder free.
29
Recommendations:
Short Term:
1) Keeping the furnace Air rich to avoid Clinkering, clean the SAH-B in next S/D to improve ID fan
margin.
2) WSB pressure setting need to check, as pressure setting work is going, but boiler tripped due to
clinkers falling.
3) Operation staff should check pressure drop of WSB, once in a month & raise D/card.
Long Term: 1) Bunker the coal having less Ash percentage & High Ash fusion temp.
2) To relace SAH-B baskets in next overhaul to improve ID fans margin, keep the furnace air-rich.
Remark:
GM-II:
30
EVENT ANALYSIS INDEX

Sr No.
Event No.
Date
Time (Hrs)
Reason
01/2006
09/01/2006
16:50
02/2006
13/01/2006
22:40
03/2006
08/02/2006
07:15
M3/2006
06/02/2006
11:00
M4/2006
09/02/2006
16:40
6
7
04/2006
M5/2006
19/03/2006
07/04/2006
09:31
15:05
M6/2006
11/04/2006
12:50
M8/2006
01/05/2006
20:23
10
11
12
13
M9/2006
M10/2006
05/2006
06/2006
20/05/2006
03/05/2006
25/05/2006
06/06/2006
15:00
13:57
02:40
16:57
14
07/2006
08/06/2006
23:14
Set tripped on Furnace pre very high due to

falling of Heavy Clinkers.
Set tripped on Flame Failure. Flash over at
6CW-II PT cubicle occurred.
Platen Reheater outlet Header tube leakage in
Pent house.
415V 6AHPA board of AHP-Bus Coupler did
not get ON, when IC-II made OFF.
ST-4 tripped on B/B protection 400KV Bus-II
problem.
Platen Reheater tube leakage.
FSSS supply failure-FSSS Unit control panel
processor application s/w erased.
TDBFP-6A tripped on Governing oil Hdr pres
low. MDBFP-D didnt pickup on auto.
TD BFP-6A tripped on Governing oil pressure
very low protection.
LHS Reheater Spray line leakage.
TD BFP-6A got unloaded.
Reheater tube leakage.
Set tripped on All BFP off protection, CEPs
were tripped on Howell level very low protn.
Wall Reheater tube leakage.
15
M11/2006
11/06/2006
23:40
16
17
M12/2006
M13/2006
24/06/2006
30/06/2006
02:20
00:00
18
M14/2006
03/07/2006
13:00
19
08/2006
13/07/2006
00:03
20
09/2006
16/07/2006
23:23
21
M15/2006
20/07/2006
09:15
22
23
24
M16/2006
10/2006
M17/2006
26/07/2006
28/07/2006
01/08/2006
04:20
23:05
11:00
25
26
27
M18/2006
M19/2006
11/2006
30/08/2006
11/10/2006
01/12/2006
13:05
05:20
07:02
CCWP6B tripped on Motor Diff protn &

6CWXA Xmer, ACWP6A & CCWP6A tripped.
Coal Mill-6C tripped without any Indication.
PCR AC plant Comp. No-3 & PCR AC Plant
Board tripped.
Relay room temp. shot upto 30.60 C.PCR A/C
Comp.No.3 tripped.
Boiler tripped on all SAH off protn. EMPA-II
tripped due to flashover occurred in Bkr trolley
to AOP-II of TDBFP-6A.
CRH spray line (RHS) NRV heavy leakage &
FRF bucket filter cleaning work.
All running Instrument & service air
compressor got unloaded.
GT-6 Main breaker circuit trouble at GCR.
GTR R-phase PRV earth cable work.
6D Bus UAT I/C breaker Gas pressure
indication circuit problem.
Ash slurry disposal line 6B choke up problem.
Abnormal sound in BSDP4 pump.
Platen Super heater tube leakage.
31
UNIT-6
EVENT ANALYSIS
2006
32

Event Ana U#6-2006

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EVENT ANALYSIS

Coal cycle in service: AB, CD, GH

Oil Support: NIL

TG set synchronisation: Time09:37 Hrs

Problem faced during bringing back the set on bar:

Coal cycle in service:

Oil Support: NIL

Boiler Light up:

TG set synchronisation: Time

Problem faced during bringing back the set on bar:

Analysis: After inspection of pump, impeller found broken.

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: six

Oil Support: NIL

Boiler Light up:

TG set synchronisation: Time

Problem faced during bringing back the set on bar:

Analysis: Series current from morning were as under08:00 hrs

(07:45 to 08:45) B/A

(08:45 to 10:45) F/A

(10:45 to 12:00) B/A

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CE, GH

Oil Support: NIL

Boiler Light up:

TG set synchronisation: Time

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD

Oil Support: NIL

TG set synchronisation: Time07: 10

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: ABCEFG

Oil Support: NIL

Description: 1) 04:20 hrs: a) GT-6 Bay breaker trip circuit trouble.

TG set synchronisation: Time

Problem faced during bringing back the set on bar

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: six

Oil Support: Nil

Description: All running Service/Instrument air compressor got unloaded

TG set synchronisation: Time

Problem faced during bringing back the set on bar:

Analysis: Control supply MCB found tripped.

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, DE, GH

Oil Support: NIL

TG set synchronisation: Time07:53 Hrs

Problem faced during bringing back the set on bar:

Work Carried Out: 1) I&C-II section: No work carried out.

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: AB, CD, FG

Oil Support: NIL

TG set synchronisation: Time05:06 Hrs

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS

POG/VARIOUS REPORT/EVENT ANALYSIS

Coal cycle in service: B, C, D, E, F, H

Oil Support: NIL

TG set synchronisation: Time

Problem faced during bringing back the set on bar:

POG/VARIOUS REPORT/EVENT ANALYSIS