unit-7 2010.pdf

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BOILER MAINTENANCE PRESSURE PARTS

STAGE III OVERHAULS 2010Sl.

No.

DESCRIPTION UNIT -VII REMARKS

01 Duration of Overhaul 01/08/2010 to 24/08/2010

02 Boiler Cleaning 1. Internal cleaning with low pressure water Done in Pass-1&22. Cleaning with HP jet -Done3. Scrapping Done over Water Wall Panel

03 Approach 1. Sky climbers 2 nos. erected

2. Quick erect scaffolding up to roof- Done3. Platform below Z panel Done4. Platen Reheater coils-4 Tier platform erected at front & rear coils5. SHDP coils -5 Tier platform erected6. Platen Super heater coils-4 Tier platform erected7. SH / RH/ Rear RH coils spacer tube approach platform erected.8. Platform for inspection of Eco inlet bends hangers at Eco hopper.9. 3-tier Platform for LTSH Terminal Tube Inspection Erected.10.For Steam Cooled wall front header stub DP platform erected.

04 Thickness survey Area No. of Spots Taken

Z-Panel 4385

Wall Blower 6732

RH Bends 303

Gooseneck 981

Burners 287

SHDP 1303

Economiser 16560

LTSH 12524

Screen Tube 1216

Terminal Tubes 1488

Lifted Coils 2423

Total

48202

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05 HP Tube Replacement Location Joints welded Radiography

PASS 1 Wall Blower 525 525

Corner Panel 47 47

Z-Panel 42 42

Reheater 15 15

TOTAL 629 629

PASS 2

Economiser 144 144

LTSH 111 111

Eco Inlet old Joints 195 195

Bifurcation 2 2

TOTAL 452 452

06 LTSH and Eco coils Lifted / Lowered Adjacent coil Top Bank

inspected

LTSH 1 / 2 & 123/124 3/4,121/122

ECO 1/2 & 183/184 3/4 & 181/182

07 Planned jobs as per

Action plan.

1. Old joints radiography 583 nos in eco inlet connection tubes.2. Platen SH I/L header all stubs DP Done in all 25 Coils.3. Steam Cooled Wall Front header stub joints DP carried out.4. In all 124 LTSH coils T1,T2&T3 was locked with Clamps at

Hanger No. 1.

5. All the orifices are removed in bottom ring header and afterhydraulic test and flushing of the headers orifices were put back in

place.

6. CRH power cycle piping Hangers replacement done as per plan.

92 joints found defected.

OK

OK

To restrict Misalignment.

8 nos. Support Hangers were replaced.

08 Non destructive testing (a)RH start up vent stub, drain stub DP.

(b)DP on fin welding.

All NDT tests completed

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(c)DP on cleats welding.(d)DP on wind box attachments.

(e)DP of steam cooled wall front header stub joint.(f) DP of platen SH inlet header stub joints.(g)Oxide Layer Thickness measurement carried out in Final RH,Platen SH

&Divisional Panel inside furnace as well as in Penthouse as per plan.

(h)30nos. DMWin FRH & 40 nos. of FRH&PSH bottom bendsRadiography done.

09 Penthouse and dead

chamber inspection andrectification.

(a)Penthouse

(b)Windbox(c)Dead chamber top(d)Dead chamber bottom.

(a)Penthouse was found clean during

initial inspection.(b)In 55 mtr dead chamber no significantash accumulation observed..

(c)10 mtr. Dead chamber seal boxes cutand replaced with new ones at all the

four corners refractory filling for

sealing.

10 Hanger inspection 1. Penthouse support inspected and loose hangers were loaded. Power cycle piping hangers inspected.

Hot & Cold Readings were taken.11 Burners (a)Coal compartments replaced.:- All were replaced with reconditioned

coal compartments.

(b)Coal compartments insitu reconditioned: - No insitu replacement.(c)Other components replaced:-Nil(d)SADC checking:- All SADCs were de linked and checked for freeness.

They were linked and checked for full opening and full closing

pneumatically.(e)Burner readings at 0,+30,-30. Carried out.(f) Oil burner alignment. Carried out.

12 Ducts (a)Cleaning.(b)Details of works carried out(c)Bracing replacement, shielding of bracing and patch welding.(d)NMEJ replacement done in Hot primary air Duct.

Enclosed:Annexure I

13 Safety Valves Drum Safety valve SV3,SV4&SV6 Servicing Done.

MS Safety Valve SV8 Servicing Done.

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All Drum & MS Safety Valve Trivi Setting Done.

All Serviced Safety valve actual floating done. Details attached:Annexure -II

14 ERV SV-9,10,12,13,22.All pilot v/v serviced15 RH attemperation valves SD 47,51&45 Servicing Done

16 SB line control valve SB 55&56 Servicing Done

17 Any other major valve CBD 72,73 & CRH NRV. Servicing Done

18 Other conventional

valves

ERV B65&66 Servicing Done

19 Valves replaced Feed water sample line v/v replaced.

20 SH attemperation valve SD-35,36,39&43 Servicing Done

21 Soot Blower Lance Tube Replaced in LRSB No. 107,108,109&110

Wall Blower at C&D elevation servicing done.

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ANNEXURE I

DUCT WORK DETAILS:

DESCRIPTION OF WORK UM QTY

Replacement of ducts bracing Nos. 318

Removal & Rewelding of Protection plate .on duct expansion joints P/Mtr. 241

Patching of duct deflector plates Sq.Mtr 225

Replacement of eroded gusset plates Nos. 159

Removal & Rewelding of shields on duct bracings Nos. 79

Replacement of NMEJ Nos. 04

ANNEXURE-II

SAFETY VALVES ACTUAL FLOATING DETAILS:

Sl

No.

Safety Valve Design Lift

Pressure

kg/cm2

Lifting

Pressure

kg/cm2

Resetting

Pressure

kg/cm2

Blow Down in

%

01 Drum Safety Valve SV 3 211.1 214 192 6.13



04 MS Safety Valve SV 8 188.5 188 182 3.19

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ANNEXURE-III

MATERIAL CONSUMPTION DETAILS:

Pass

1

OH

Works

:

Material

Code MaterialDescription Unit Qty Amount

M0521990532 SPRLWOND

METLC

GASKET

SS316

GRAPHITE

FI

NO

10 4602.00

M1661210209 HOSEWATER:IS:444:1.0MPa:20MM M 120 8040.00

M1661210227 HOSEWATER:STD&GRIS:444:21MPaPR:25MM M 76 5335.96

M2450321524 TIGFILLERROD:MODEL/:2.40TGSM KG 10 5805.20


M2450321551 WELDINGACCESSORIESTIGSIZE 2.4MM KG 10 7543.60

M2450341753 WELDINGACCESTIGFILLERWIRE2.4MM KG 5 4123.35

M4706020557 WALLBLWRBEND 51X56MMSA210RIFLED NO 18 65757.96

M4706020575 WWBEND51X5.6MMSA210RIFLED. NO 20 95818.40

M4706040768 FINBAR6X12.7BMC20FORWWTUBES KG 400 44160.00

M4706130012 WWRINGHDRMANHOLESBOMO2SMA1H430 SET 1 799.21

M4716020246 U7RHBENDTUBED63.5X4MMR200,60DEG NO 1 6666.40

M4716020255 U7RHBENDTUBED63.5X4MMR200,120DEG NO 1 6666.40

M4772100089 WATERWALL

SMOOTH

TUBE

51X5.6

SA210

GR

C

M

250 241467.50M4772100353 RIFLETUBE51X5.6MMSA210GR.C M 100 302648.00

M4772100353 RIFLETUBE51X5.6MMSA210GR.C M 200 605296.00

M4772290078 ST.TUBE54.0X4.0MMSA213T22 M 0 0.00

M4772450076 ST.TUBE63.5X4.0MMSA213TP347H M 20 121841.40

M4741010090 CARNSEALRNGSBOMO2SMA3U1780OILGUN SET 5 2628.20

M4741010133 PINFOROILBURNRTILTSBOMO2SMA3U4180 NO 10 464.97

M0540153057 PKGG:IS:4687/1

DRY

AS:SQ:3MM

NO

35 13297.90

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M0590113001 ASBESTOSCLOTHSTRIP 3MM(T)X65MM KG 51 10546.09

M4741010160 FLEXSEALTUBEASSYSBOMO2SMA3U0240 NO 8 9886.00

M4745010010 GKTFOR

COUPLG

24

FOR

COAL

BURNER

NO

24 9792.00

M4745020107 SQHDPIVOTPINSMA3U0730FORCOALBUN NO 10 1731.08

M4745020116 REACDENDSBOMO2SMA3U1320FORCOALBUNR NO 10 439.01

Total

1584064.43

Pass2OHWorks:MaterialCode MaterialDescription Unit Qty Amount

M0171110249

RODSS

CIR

AISI:304

6MM

KG

50 10390.50

M0141200259 SHEETSSAISI:3042.5MM MT 1.344 308827.87

M0141200259 SHEETSSAISI:3042.5MM MT 0.96 220591.33

M0521990532 SPRLWONDMETLCGASKETSS316GRAPHITEFI NO 3 1380.60

M1661210209 HOSEWATER:IS:444:1.0MPa:20MM M 122 8174.00

M2415022552 ELECTRODESSRESISTING 308163/3.15MM NO 483 4801.02

M2415032029 WELDINGELECTRODEE309L16; 2.5X350MM NO 960 24278.40

M2415032029

WELDINGELECTRODE

E309L

16;

2.5X350

MM

NO

768 19422.72

M2415082024 WELDINGELECTRODEE8018B2 2.5MM*350MM NO 625 3193.75



M2450321551 WELDINGACCESSORIESTIGSIZE 2.4MM KG 5 3771.80

M4704020047 FIXGBLTFORDRUMMANHOLEDOOR SET 2 1442.00

M4711070060 SHSCFRONT6X100MMBMC20FORSH KG 200 16920.00

M4711080111 ALIGNTCLAMPLTSHCOILS500MW.BLRSTII NO 100 85197.00

M4711080111 ALIGNTCLAMPLTSHCOILS500MW.BLRSTII NO 100 85197.00

M4711990105 STRAIGHTTUBE51.0X10.0MMSA210GRC M 20 17689.60

M4772100131 TUBE44.5X7.1MMGRADE:SA230T11. M 20 15424.40

M4772100168 ST.TUBE47.63X6.6MMSA213T11 M 50 222862.00

M4772100210 ECONOMISERSTTUBESA210GRA1FORU7 M 150 83935.50

Total

1145109.893

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M1149200885 HSDVehicle L 3 115.21

M1149200885 HSDVehicle L 10 401.76

M1149200885

HSDVehicle

L

10 399.67

M1149200885 HSDVehicle L 5 203.95

M2730250029 MARKEENCLOTHWIDTH90CM3640GMS/SQ.MTR M 10 0

M2801990039 WHITECOTTONYARNWASTE(TEASED) KG 3 89.79



M4725010003 DISCFORDRUMSAFTYV/V1740OF500MW NO 1 8,567.39

M4725010003 DISCFORDRUMSAFTYV/V1740OF500MW NO 2 17,134.78

M4725070007 CSEALRNGFORERVISOLGV/VBHEL NO 1 30,092.01

M4725070007 CSEALRNGFORERVISOLGV/VBHEL NO 3 90,276.04

M4725070089 SEATBUSHGGKTFORERV1538VX NO 3 10,221.83

M4725070195 PILOTV/VDISCFORRHOUTLT6ERV NO 1 3,878.80

M4725070308 DISCFORMAINVALVEOFERV1538VX10W NO 1 24,078.00

M4725330188

GASKETSET

SH.ATP.CONT

V/V.SNO2815854

SET

2 20,309.87

M4725330507 GLANDPKGFORU7SHSCVSD4043 NO 2 2,307.50

M4725340137 GASKETSET RH.ATPCONTV/VSNO.2815939 SET 2 7,960.19

M4725340199 COUPGFORRHCVSBOMO5SMA3H0120 NO 6 1,716.00

M4725340205 GLNDPKGFORU7RHSPRAYCVSD4952 NO 2 2,307.50

M4725350078 GLANDPKGSETFOR40%SB.CONTV/V. SET 1 16,318.39

M4725350081 GLANDPKGFORSB.CONTV/V.S.NO.2817468 SET 1 16,318.40

M4725420025

gasketset

of

SH

Atep

blk

V/VS.NO2815836

SET

1 13,100.21

M4725430026 GASKETSETRHATTEPBLKV/VSNO2815820 SET 2 7,960.19

M4725430081 GLNDPKGFORRHSBVSD4548 NO 2 3,907.00

M4725430106 VALVETRIMFORRHBRANCHBLCKV/V SET 1 47,341.75

M4725430106 VALVETRIMFORRHBRANCHBLCKV/V SET 1 47,341.75

M5101126060 PRESSURESEALGASKETFORCRHNRV NO 1 35,782.50

M5105020014 STEM&DISCASSEMBLY25NB,F22,2500CL NO 1 3,813.33

Total

5,32,427.64

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DuctsOHWorks:

MaterialCode MaterialDescription Unit Qty Amount

M0105160128 ANGLEEQIS:2062E250AFE410W75X6MM MT 2.93 1,06,062.10

M0135102525 PLATEMSIS:2062E250AFE410W5MM MT 8.02 3,30,244.59

M0135105029 PLATEMSIS:2062E250AFE410W10MM MT 2.3 95,883.32

M1613342370 PMSB2:IS:1239PT1H:80X88.9:4.50 M 61.45 21,836.26

M1613348527 PMSB2:IS:1239PT1H:100X114.3:7.10 M 330.22 1,94,225.50

M1613355439

PIPEMS

BL

PII:1239

PT1H:125X146:5.40MM

M

99.2 64,080.22

M1514145821 SCREWHEXHT:IS:1364:COARSEMC:24X65MM NO 200 9,180.00

M1515142560 8.8HTFTHREADHEXHD.BOLT/NUTM10X100 NO 200 2,142.00

M1515146429 BOLTH.HD:IS:13648.8:24X100 NO 100 6,517.80

M1525244012 STUDFERROUSIS1862P.C.8.8M16X100 NO 300 6,089.40

M1528342960 STUDFERROUSTHREDED:IS:1862 H.T12X80 NO 300 2,417.40

M1515142870 BLTHEXHT:IS:1364:MC:12X60MM NO 1,500 13,045.38

Total

8,51,723.97

ReplacementofNMEJ


M4748130032 NONMETLCEXPNJNTFABCKEB2005IN M 35 2,41,073.12

M4748130023

NONMETLC

EXPN

JNT

FABC

KEB

2005IN

M

35 4,39,954.04

Total 6,81,027.16

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Insulation

&

Refractory:


M0362454501 SLABBONM:IS:8183:BULK150:50MM M2 1,334.17 2,04,313.92

M0440310509 REF/INSUCAST:MONOLFIR:Al2O3&Fe2O3 MT 2 28,469.92

Total 2,32,783.84

Hangers

Replacement

in

CRH

Line:


M4715016014 H&SITEM:HANGERASSY. NO 8 16,52,000.00

Total

16,52,000.00

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UNIT 7 OVERHAUL 2010 EXPENDITURE:

Sl.

No.WorkDescription P.O.No. Agency Works Material Total

1

HP tube replacement Pass1 &

Burner repair 4000048461 M/s Fab Erectors 3475070.50 1584064.43 5059134.93

2 HP tube replacement Pass2 4000049014M/s Brothers Engg & ErectorsLtd.

2455525.43 1145109.89 3600635.32

3 Tube thickness survey 4000039090 M/s Sans Inpection 227022.26 0.00 227022.26

4 HP Jet cleaning 4000039076 M/s Nutech Jetting 148844.34 0.00 148844.34

5 Erection of quick erect scaffolding 4000044132 M/s Prabhat Engineering Works 663815.20 0.00 663815.20

6 Pressure setting of safety valves 4000038103 M/s Nicco Engineering Services 61768.00 0.00 61768.00

7 Servicing of HP valves 4000041949 M/s Hydraulic Valves 204619.45 532427.64 737047.09

8 Refractory & Insulation works 4000042283 M/s ABC Engineering Works 1046693.21 232783.84 1279477.05

9Maint. Of LRSBs, Burners & Misc.works

4000030401 M/s Noorie Engineering Works 967622.38 851723.97 1819346.35

10 Ex BHEL Services 4000039630 M/s ABC Supevisory Services 241936.43 0.00 241936.43

11 Repl. Of Hangers in unit 7 4000047790 M/s Noorie Engineering Works 385608.80 1652000.00 2037608.80

12 Repl of NMEJ in Unit7 4000050384M/s KE Burgmann FlexiblesIndia pvt Ltd.

49635.00 681027.16 730662.16

9928161.00 6679136.94 16607297.94

Documents

unit-7 2010.pdf