LONG TERM PLANNING AND OVERHAULING PRACTICES IN NTPC

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WHY OVERHAULING IS REQUIRED ?

Performance Reliability Availability Safety Environment Cost Statutory Requirement

PRASECS
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PERFORMANCE
Generation Heat Rate Parameters Specific oil consumption Auxiliary power consumption Motor current Capacity deterioration Utilising stand by eqpt.
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RELIABILITY
Routine and repetitive maint. Poor performance of eqpt. Unplanned Breakdowns High vibration of eqpt. Abnormal noise High Temperature Leakages

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AVAILABILITY
ABT Availability of stand by eqpt. Availability of complete stream

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SAFETY
Safety of the equipment Safety valves Poor condition of internals Safety of electrical eqpt. Condition of flow path

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ENVIRONMENT
Flue gas emissions Air control act Noise Ash water Effluents

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COST
Cost of generation Coal input Water consumption Oil consumption Auxiliary power consumption

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Statutory requirement
Boiler certificate renewal

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WHEN TO DO OVERHAULING ?
Summary of

PRASECS

Grid condition Customer requirement CERC Clearance Condition of other units of the station MOU Target

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LONG TERM PLANNING

Life cycle plan for 25 30 years Regional Eight years rolling plan Station Eight years rolling plan Engineering declaration Annual location plan Spares procurement plan

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OBJECTIVES OF LONG TERM PLANNING

O2O MAINTENANCE (ZERO FORCED OUTAGE) OPTIMIZE COST OF MAINTENANCE QUALITY FOR RELIABILITY SYSTEMS APPROACH

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OVERHAUL MANAGEMENT PROCESS

REB NTPC-CC NTPC-RHQ NTPC-REGIONAL PLAN & BUDGET STATION LONG TERM PLANNING
STATION LOCATION PLAN

CENTRAL POOL OF SPARES

CENTRAL WORKS & BUSINESS ASSOCIATES

MFG. WORKS

SITE QUALITY

VENDORS

RESOURCES QUALITY TIE-UP CC-OS RHQ-OS OUTAGE CONTROL ROOM

MATERIALS

OPERATIONS

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MAINTENANCE

STRATEGIC PLANNING PROCESS FOR UNIT OVERHAULS

To this effect a four tier planning system has to be evolved as follows

Life Cycle Plan Regional Rolling Plan Station Rolling Plan Station Location Plan

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LIFE CYCLE PLAN

Likely trend of replacement of the equipment/parts which are likely to fail before the life expectancy Factors for replacement Coal quality Creep life of various components Equipment duty conditions Wear rate Behavioural trend of plant/ equipment & its past history RLA Reports
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LIFE CYCLE PLAN (TYPICAL)

Years 01 02 04 Activity Description Statutory Inspection, Coal Burners, APH Seals. Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil Reversal, DC Batteries Replacement

08

16

Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables

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Statutory Inspection, Coal Burners, APH Seals. ECO/LTSH bends & tubes, Refractory, ESP Electrodes, ID Fan Impellers, Defective Valves, APH Baskets, PF Bends, ECO/LTSH Coil, DC Batteries HP/IP Turbine Blades, Diaphragm, Casing Studs, HP/IP CV/GV Bolts, Turbine Bearings, Turbine Inter stage seals, Electrical Cables, Control Cables, Heaters/Condensers/ Heat Exchangers tubes/tube nest etc.
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MAJOR EQUIPMENT TO BE COVERED IN LIFE CYCLE PLAN

Gear Reducers Slurry pumps Coal crushers Conveyor Drives in CHP Chemical piping

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Contd

Boiler Pr.Parts
Super heaters Re-heaters High Pr. Valves Safety valves

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Contd
Turbine & Aux. Turbine rotor blades Turbine bolts Boiler feed pump rotor H.P. Heater coil

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Contd
Electrical H.T.Motor Transformer Switch gears Cables

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Regional Eight years rolling plan

Minimum number of units at a time Regional electricity boards Regional grid demand Capital investment and revenue budget Unit/station merit rating based on efficiency and economics of generation

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 Detail plan for first three years Diagnostic inspection and major replacements in subsequent years Modest updating each year

Station Eight year rolling plan

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Station annual location plan

Detailed account of operation and maint. Of the current year and plans for the next year. The plan should consist Unit merit rating based on its performance in the last one year. Justification of heavy expenditure for improvement and modifications Resource availability analysis Fuel cost Generation cost

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6-Year Rolling Plan of a Coal Station (Typical)

Stn/Unit Cap Last O/H Done Rihand Unit-2 2 2HPT 2 IPT LPT Gen Blr 2 2HPT 2 IPT LPT Gen Blr 22 22 2 -Nov-2 2 2 2 -Oct-2 2 2 2 -Oct-2 2 2 2 -Nov-2 2 2 2 -Nov-2 2 2 2 -Oct-2 2 2 -Oct-2 2 2 -Oct-2 2 2 -Oct-2 2 2 -Sep-2 2 2 From To Duration O/H Type

FY 2222 -22FY 2222 FY 2222FY 2222FY 2222FY 2222 -22 -22 -22 -22 -22

2 -Aug-2 2 -Aug-2 2 -Aug-2 2 -Aug-2 2 -Aug-2 2 -Aug-2 2 2 2 2 2 2 2 2 2 2 2 2 2 -Sep-2 2 -Aug-2 2 -Aug-2 2 -Sep-2 2 -Aug-2 2 2 2 2 2 2 2 2 2 2 2 -Sep-2 2 2d 2 2d 2 2d 2 2d 2 2d 2 2d 2 Boiler Boiler Boiler Blr+IP+LP Boiler B+HP

Unit-2

From To Duration O/H Type P/M (%)

2 -Sep-2 2 -Sep-2 2 -Sep-2 2 -Sep-2 2 2 2 2 2 2 2 2 2 -Sep-2 2 -Sep-2 2 2 2 2 -Oct-2 2 -Sep-2 2 -Sep-2 2 -Sep-2 2 -Sep-2 2 -Sep-2 2 2 2 2 2 2 2 2 2 2 2 2 2d 2 2d 2 2d 2 2d 2 2d 2 2d 2 B+HP+Gen Boiler Boiler Boiler Blr+IP+LP Boiler 22 . 2 22 . 2 22 . 2 22 . 2 22 . 2 22 . 2

Total

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ROLLING PLAN PREPRATION FLOW CHART

Define Region into Station/Plant & areas Engineering input from Similar plants Maintenance Engineer input

Consider plant life & potential problems in each station/units

Statutory Requirements

Formulate repair Plans With Cost data

Plant Betterment Plans

Resource Spares & materials

Evaluate Interim Plan

Resource Skill and T&P Management Input

Region/Station Rolling Plan

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Station Location Plan

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OUTAGE CATEGORY & DURATION OUTAGE CATEGORY

For Thermal Units : Minor Overhaul : Budgeted outage not exceeding seven days. Medium Overhaul : Budgeted outage above seven days & up to twenty
days.

Major Overhaul : Budgeted outage exceeding twenty days. For Gas Units : Category A Inspection: Budgeted outage not exceeding seven days Category B Inspection: Budgeted outage above seven days & up to ten days. Category C Overhaul: Budgeted outage exceeding ten days

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OUTAGE CATEGORY & DURATION OUTAGE DURATION

S. No. 01 Unit Size (MW) Up to 250 MW Major Work Area Boiler Overhaul Turbine Overhaul (all cylinders) 02 Above 250 MW Boiler Overhaul Turbine Overhaul (one or all cylinders) Duration (days) 20 30 25 35

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OVERHAUL PLANNING PROCESS

The single most important & foundation of overhaul planning process is the work planning. Each activity to be done need to be justified in terms of:

1.0

Operational inadequacies:
AI = Availability Improvement RI = Reliability Improvement EI = Efficiency Improvement

2.0

Statutory requirements:
SR = Statutory Requirement EN = Environmental inadequacies

3.0

Major plant modifications:

TO =Technological Obsolescence CO = Commercial objectives & competitions

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OVERHAUL PLANNING PROCESS

Planning and Budgeting Process: should be sufficiently flexible to accommodate changes of the type described above, allowing a rapid reoptimization of the agreed Plan and Budget and any consequential revision of budget allocation and work implementation plans for the units planned for overhaul. A large number of the activities is repetitive in nature and therefore it is desirable to develop a 'Standard work Module' for Minor, Medium and Major nature of unit overhaul
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Brief review of the past performance of the unit Objectives of the proposed overhaul Scope of work Resource plan Returns in terms of gain in reliability and efficiency Engg declaration to be issued 24 months ahead and reviewed periodically (six monthly)

ENGINEERING DECLARATION

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Unit no Boiler license no Boiler license validity Overhaul history Unit mile stones/ Major event Unit performance history Root cause analysis on Boiler tube leakages and action plan Root cause analysis on trip and action plan

Format of Engg. Declaration

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Contd
Major eqpt. Failure history Parameters assessment Work module Financial justification Techno economic evaluation Bar chart Exception of condition monitoring reports

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 Pre shut down planning activities Shut down activities Post shut down activities

Planning process of unit outage

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PLANNING PROCESS FOR UNIT OVERHAUL

Pre shut Down Planning Job List Bill of Material Skill & Manpower Indent & Procurement

Maintenance QCS

Resource Analysis

Tender & Contracts

Recommissioning Check sheets

PERT Net work

Resource Mobilization

Isolation Plans Monitoring sheets Quality Checks Re commissioning checks Outage 24, 2012 May Completion Report Post O/H Review UNIT ON BAR

Pre Outage survey

Overhaul Execution

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Overhaul Monitoring

Pre shut down planning activities

Plan to start from the time unit is synchronised. Engg declaration Spares and materials schedules Quality plans Recommissioning Schedules Defect work orders pending PRE SHUT DOWN SURVEY

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Resources
Spares & consumables Manpower Contracts Special T&P Material handling equipment like cranes, lifts and transport Availability of manufacturing facilities Communication facilities

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Contd
Testing facilities like radiography, hydro test etc. Temporary store & office cubicles Dispensary & ambulance at site General amenities for additional work force Input from other departments

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PRE SHUTDOWN SURVEY

Equipment general condition Condition of bearings, filters and coolers Condition of APH Pressure differential Heat pick up across APH Parameters of primary ,secondary air & flue gas Oxygen in flue gas

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Contd ESP Ash evacuation capacity Heating system Flue gas emission Leakages through manholes ESP inlet & outlet Temperatures.
Coal mills Reject rate Coal fineness Leakages
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Contd Boiler Boiler expansion Leakages through manholes, peep holes Coal leakages Burner tilt mechanism Soot blower status Valves & Fittings Steam leakages Steam passing Local/remote operation
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Contd
Ducts & Dampers Hot air leakages Air suction in the gas path Ash leakages Leakages at expansion joints Dampers operation from local & remote Dampers isolation Duct insolation
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Contd
Turbo Generators Bearing condition Vibration & Temp Oil leakage Analysis of lub oil Operation of control valves Leakage of hydrogen Stator water DP

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Contd
Motors Bearing vibration Lubrication & Temp. rise Transformers General condition of oil Dielectric strength

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Execution
Unit shut down Issue of PTWs Daily overhaul review meeting Follow up of the bar chart Filling the quality check sheets Return of PTWs Recommissioning activities Boiler hydro test Unit light up Unit synchronisation

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Post overhaul review

Deviation from the planning if any Performance of contracting agencies Plant parameters review Overhaul report

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SCOPE OF WORK

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PRESSURE PARTS
WATER WALL
S-Panel: All corners & L&R walls inspn. & repairs Burner transition & corner tubes inspn. & repairs, TT survey in erosion prone areas, HP Jet cleaning, DPT of scallop bar, support & ww tubes in dead chamber, Bottom ring header inspn. WW screen & hanger tubes inspn. Coils lifting (condition based), Inspection of Bifurcation bends, Cassette baffles & Terminal tubes inspection DPT of hanger tubes & TT survey Spacer tube healthiness checking & TT survey DPT of Lugs to tube welding Scissor tubes sleeves, lugs inspn. & repairs and DPT of Lugs to tube welding, TT survey TT survey in Screen tubes, tubes near manholes, Gap between LTSH coil & steam cooled wall, Eco coil& SCW, mechanical rubbing due to cassette baffles, stubs of SHH-4A &4B
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LTSH PLATEN SH / FINAL SH DIVISIONAL SH STEAM COOLED WALL

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PRESSURE PARTS
REHEATER ECONOMISER

CONTD..

Spacer tube healthiness checks & lugs inspn. ORIFICE FIXING ? & TT survey Coils lifting (Condition based) DPT of root joints of stubs of Inlet header Cassette baffles & hanger tubes inspection & TT survey

DRUM HANGERS SAFETY V/Vs & ERVs SOOT BLWRS PENT HOUSE
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Drum inspection Drum J-bolts inspn. & DPT Pre O/H & Post O/H readings comparision Survey of Cold readings & Adjustment, if any Defective Safety valves & ERVs (Condition based) overhauling/Servicing Soot blowers overhauling & LRSBs servicing Inspection of supports, headers, vents, DPT of roots, attachment weld joints& all header joints
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PRESSURE PARTS
BURNERS
36 NO.S of Coal nozzles replacement Air/oil nozzles in-situ repair (condition based) SADC/BURNER TILT CHECKS

CONTD

NMEJs QUICK ERECT SCAFFOLDING WIND BOX BOILER EXPANSIONS HP VALVES BOILER SUPPORT SYST
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Repair & Rectification of defective portion of joints after preoverhaul survey Erection of QES and Thorough inspection & cleaning of Water walls, Divisional panel Cleaning, Inspection & repairs Expansion indicators checking for any fouling problems

CC pump- discharge v/v bonnet leakage, CBD v/vs, MS, Spray v/vs, root valves gland packing replacement Boiler support systems checks as per LMI
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ROTATING MACHINES
MILLS FEEDERS DAMPERS & GATES FANS AIR PRE HEATERS
2 No.of Mills Overhaul , Lub station servicing 8 no.of RC feeders overhauling Dampers & gates overhauling & Passing problems rectification All fans servicing, Blade pitch control servicing, silencer cleaning, Visual inspection of shaft, welds & NDT. Lub station servicing. Damaged baskets replacement, if any Radial / Axial seals inspn, repairs & replacement All bearings/ gear boxes inspection Overrunning clutches problems attending. SCAPH heat transfer areas inspn , cleaning & repair

DUCTS & DAMPERS

Air & Gas duct inspection & repairs Repair of defective dampers & servicing of diversion dampers

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ASH HANDLING SYSTEM

BOTTOM ASH SYSTEM Repair of refractory, Seal trough & view glasses inspection & cleaning, Clinker grinders rollers (2 sets) replacement, SS pipes replacement, Feed gate seal & barrel replacement & attending to passing problems, Bottom ash nozzles inspection BA discharge new lines connection

FLY ASH SYSTEM Fly ash slurry line rotation/ replacement, Collector tanks & Air washers inspection, Vacuum line valves servicing, All vacuum lines washing, Vacuum pumps servicing, Collector seal boxes repairs. ESP Emptying of all hoppers All ESP internals cleaning,inspection/ repairs
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TURBINE & AUXILIARIES

MAIN TURBINE
CF trip oil line modification for proving ATT, & Turbine Governing characteristics checking, Turbine actual over speed testing Euroflex coupling inspection, Turbine actual overspeed test, MDBFP-2C discharge NRV replacement, ACV & MCV pilot valves servicing & recirculation control valves inspection & repairs. TDBFP-2A&2B exhaust duct insulation & plastering DMCW pump-B overhaul & suction strainers cleaning DMCW,ACW & CW system butterfly valves servicing (600 NB: 6 no.s, 800 NB : 8 no.s) PU coating inspection & repairs, Self cleaning filters inspn Condenser Water box tube cleaning, FRE lining inspn Hotwell & Deaerator cleaning & condenser flood test CEPSs suction strainers cleaning. CW duct PU coating inspection & repairs. Turbine MAL valves, HTPRDS spray valves
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TDBFPs

DMCW & ACW

CONDENSER

CW DUCT VALVES
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OFF-SITES (MECHANICAL)
CW PUMPS CW pump- 3,4 & 5 volute inspection for poly -glass coating. CW pump butterfly valves inspection & operational checks

CW DUCT

CW inlet & Outlet duct inspection repairs.

& PU coating

COOLING TOWER CT nozzles inspection / cleaning CT nozzles & drift eliminators repairs / replacement. CT basin cleaning.

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EM-LT SWGR
LT switch gear sections overhaul Bus/Modules/breakers/relays/contactors/tr ansducers/timers Cable shifting / interchanging Testing of protections of incomers/ bus couplers / auto change over schemes as per LMI

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EM-SWYD / HT SWGR
Insulators replacement CTs replacement Bus tightness HT switch gears PM

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EM-GENERATOR
Stator & Rotor Inspection Core inspection Hydrogen & Exciter coolers servicing Exciter servicing Testing of excitation as per LMI Inspection & protection of water cooled generator stator winding Prevention & detection of generator rotor earth faults as per LMI

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TRANSFORMERS
Transformers cleaning OLTC, Conservators cleaning Protection elements checking Silica gel replacement Oil sampling Oil flushing Testing

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HT & LT Motors
Overhauling of motors Servicing of motors Bearings Oil replacement / Greasing Lugs inspection Fan inspection

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LIGHT-UP TO SYNCHRONISATION
ACTIVITY LIGHT-UP TO SYNCH. UNIT-1 (2003-04) UNIT-2 (2004-05) UNIT-1 (2004-05) UNIT-2 (2005-06) UNIT-1 (2005-06)

25 Hrs

24.5 Hrs

20.8 Hrs

20.0 HRS

18 Hrs

LIGHT-UP TO SAFETY V/V FLOATING START SAFETY V/V FLOATING DURATION SAFETY V/V FLOATING TO TG 3000 RPM ELECTRICAL TESTS DURATION May 24, 2012

7.2 Hrs

6.7 Hrs

6.5 Hrs

14.4* HRS

12.5 Hrs 4.4 Hrs 0.9 Hrs 4.3 Hrs

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5.5 Hrs

5 Hrs

3 Hrs

4.5 HRS

5.2 Hrs

3.3 Hrs

4.5 Hrs

0.8 HRS

5 Hrs

7.75 Hrs
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6 Hrs

5.0* HRS

QUICK ERECT SCAFFOLDING

UNIT-1 UNIT-2
(2003-04) (2004-05)

PRESSURE PARTS (Contd)

UNIT-1 UNIT-2
(2004-05) (2005-06)

QES ERECTION

8.5 DAYS

7.0 DAYS

5.5 DAYS 5.5 DAYS

QES DISMANTLING

4.5 DAYS

2.0 DAYS
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2.9 DAYS 3.0 DAYS

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FUEL OIL CONSUMPTION

UNIT # I # I # II # II #I
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YEAR 2003-04 2004-05 2004-05 2005-06 2005-06

HFO KL 228 243 251 148 PMI Revision 00

LDO KL 224 38 151 141 -

TOTAL KL 452 281 402 289 170

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OVERHAUL MANAGEMENT-ORGANISATION

OUTAGE COMMITTEE

This committee will be responsible to conduct the overhaul of all the units of a station during a particular financial year as planned and shall ensure that all the jobs are carried out as per laid down specifications and quality plans. The committee may change for next financial year according to availability of personnel and workload of the station. The various members of the outage team shall be as follows:

a. Outage manger b. Executive: Long Term Planning c. Executive: Maintenance contracts d. Executive: Boiler and Aux. e. Executive: Turbine and Aux.
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f. Executive: Electrical g. Executive: C and I h. Executive: Operations i. Executive: Operations Efficiency j. Executive: Materials

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FUNCTIONS OF AN OUTAGE COMMITTEE

(a)To assess skill availability and the technical capability of the contractors. (b)To coordinate amongst different working departments and contractors. (c)To Check and ensure that the job execution is as per technical specification and work quality is being complied as per Q.A. plans. (d)To ensure observance of safety rules as per laid down principles of the company. (e)To monitor work progress to ensure timely work completion, reduce down time and cost. (f)To ensure optimum utilization of resources. (g)To coordinate for an effective work control. (h)To facilitate de-bottle necks in planning and take appropriate measures for improvements and effective planning.

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OUTAGE PREPAREDNESS INDEX (OPI)

Outage Preparedness Index (OPI) is devised to be a tool to measure the degree of preparedness to execute the planned outage. It provides a quantified measure of the Degree of

Preparedness
for planned outage of a given unit overhaul. OPI monitoring shall begin 100 weeks in advance of the proposed planned date of unit overhaul. The stage includes a set of activities as defined in OPI: ZERO wherein each activity shall be completed.
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OUTAGE PREPAREDNESS INDEX (OPI)

It is envisaged that unit outage committee shall be formed 52 weeks (12 months) prior to propose planned date of first unit overhaul and shall take up all the unit overhauls of the financial year. At OPI: FIFTY (Fifty weeks prior to overhaul), outage committee shall hold its review The total responsibility of overhaul planning, preparedness, resource organization and mobilization, execution and post overhaul activity shall be taken over by the outage committee. At OPI: HUNDRED (Four weeks prior to overhaul) preparedness must be 100% to allow overhaul to take place as per schedule. Each stage of OPI monitoring shall include a set of activities. A typical such list is defined in the annexure.

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OUTAGE PREPAREDNESS INDEX (OPI)

Each activity shall be graded carrying marks which shall be obtained by either of the following methods: By law of equal criticality: All identified activities shall be listed serial wise in a sequence. Each activity shall be allocated equal criticality and therefore equal marks for each activity shall be allocated. By law of determined criticality: All identified activities shall be listed. Each activity shall be allocated priority based on criticality. Marks for each activity shall be determined based on criticality of the function. Sum total marks of the competed activity shall indicate the percentage completion of each stage OPI. It is envisaged that all actions shall ensure that each OPI is 100% completed.

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OUTAGE COMPLETION REPORT

Each completion report should bear a unique number for identification. The cross reference of the completion report should be entered in the equipment history. SECTION-1: EXECUTIVE SUMMARY SECTION-2: BOILER & AUXILIARIES SECTION-3: TURBINE & AUXILIARIES SECTION-4: GENERATOR & AUXILIARIES SECTION-5: ELECTRICAL EQUIPMENTS SECTION-6: CONTROL & INSTRUMENTATION SECTION-7: OFFSITES AND MISCELLANEOUS SECTION-8: RECOM MISSIONING & EFFICIENCY EVALUATION SECTION-9: MANPOWER & BUDGETS SECTION-10: CONCLUSIONS AND RECOMMENDATIONS
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THANK YOU

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