EVENT ANALYSIS REPORT

UNIT NO : 5 ITPS: Khaperkheda TPS Unit Capacity: 500 MW

Date:- No. of days frorn last sync.:- 87
1, *HO Code: Station Code:-TE O8l L5-15 Time:- 12:17 Hrs.
22.L2.2015 Days
2. Operating conditions at the time of Event
Load MW Coal Cycles in service Oil Support
477 I A,B,C,D,E,F NIL
3. Nature of Event : Set withdrawn for Boiler validity extension. Coal mills withdrawn one by one. TDBFP's withdrawn &
MDBFP taken l/S. Turbine hand tripped @ load 183 MW.

4. Name of First Up, Main Protections & protection on which GCB tripped:
Boiler Tripped On:- Turbine Tripped.
Turbine Tripped On:- Hand Tripped.
5. A) Observations :- Set withdrawn for Boiler validity extension.
5. B) Remedial Action/work done I

I NA

9. Crtr" Anrlytit r M
Root
Tveventive action suggested (Short Term) NA
8. Preventive action suggested (Long Terrn) NA

9. Similar event occurred last time: TE: Time : Date :

9A. lmplementation Status of Long Term/Short Term measures stated at sr No 9:- NA.

10. Boiler lighted up Time - 2O:45 Hrs. Date- 24.L2.20I5

11. T-A Set Synchronised Time - A4:OZ Hrs. Date- 25.L2.2OL5

L2. Remarks

Chief Engin-eer
Khaperkheda TPS

'-Recommendations of Works Section:

1. Procurement/Replacement Plan:
2. Operational Error:
3. Delay in Maintenance:
4. Delay in bringing back the Unit:
5. Training of Staff:
5. Whether remedialaction is completed satisfactory & point is closed :

CElDyCE(Works)
*HO Code will be given by Works Section,
I

I
 Doc. No.
KHAPERKHEDA T.P.S. Rev. No.
Rev" date :

TRIPPING T NON.TRIPPING EVENT ANALYSIS REPORT

A) TO BE RECORpED BY Om
1> EVENT r$rfE: ] L' 17 DATE: L-2-^ I Lt w(7
2> OPERATING CONDI|qNSATT|ME OF EVENT :

t(77
"=:= W ryu
-L9AD(MW)
.. lAtlz-D'E,.F.c W
MVAR I

} BRIEF DESCRIPTION OF EVENT / SEI r TRIPPING .

uhil- LDlw)ru) a fu $o,'[>v, Vaj""/* ex-fu-sidq,

co-a *lL #1,1A Anrnt H L? A -\L " 7D ffily-t/rfu K n b$fp)
t4/kT/r,M i bJt@a Lo4 I*l t'-t* '
4> WINDOW INDICATIONS APPEARED 5> REISY OPERATED ON GEN./GTR/UAT PROT. PANEL

6> FIRSTUP OPERATED :

7> ABNoRMALTTES, rF ANy,oBSERVED BEFoRE & DURTNG sET TRrpprruc i nrElt'

E> BRINGING BACK THE SET ON BAR (rN CASE OF SET TRtpplNG):
BOILER LIGHT UP .
TIME: Zo lr f llW DATE- L+- l?^ ry(-
TG SET SYNCHRONISATION TIME: &+-eZ*
Kyt DATE; 2*T - tL - Ze(r
1o' pRoBLEM FAcED DURTNG BRTNGING BAcK THE sET oN BAR / NoRMeltsnrtoN
.a

SHIFT INCI'IARGE r

NAME ,- V,'. hrn q.-1. E'. Jorn l440rg e

B) ro ee
1> ANALYSIS OF TRIPPING & PROBLEM FACED DURING LIGI{T UP & SYNCHRONISATION:-

2>WORKSTCARRIED OUT :- De-*<-+)-r.s ocrtcrAov E coo,ucs czvr^'tel

-t6 g,rnc-l"'g-g.d ca./\^{el ou.J*
orJ {"r-z"i\ t...&,f*

3>
coRRECTtVE ACTTON TO AVOTD REOCCURRENCE OF ABOVE : RESPONSIBILITY TARGET DATE

Fr 1f \l_ 1(\\d
>
E.E.( TESTINc-ll-f E.E.( C&l)}y)
NAME:- V, A. De &6a -r
NAME:- V,A . Dcg.p'.r
a

) i
c) To BE RECORDED BY MAINTENANCE SECTION :
1> ANALYSIS OF TRIPPING & PROBLEM FACED DURING LIGHT
UP & SYNCHRONISATION :-

2> WORKS CARRIED OUT :-

RESPONSIBILITY TARGET DATE

CORRECTIVE ACTION TO AVOID REOCCURRENCE OF ABOVE
:-

O"/{r/ 0Y/ r* Ytuu't)ru

trsf + yqr$dlu /,/wk clwzt'ei gt*
e.tvide.i ;'

e.e.( en-nt'l'
E.E.( E
9. . Sa,T'u 3<-
D> REMARKS:

s.E. ( OP-ll )

DY. CHIEF ENGINEER-II

Note :- Please attach Separate sheet, where required"

Note :- Please attach DAS alarm & Trend Curve print out

.r a
 WORK CARRIED OUT DURING SHUT DOWN DTD. 22.I2.I5TO 24.L2.I5
Sr.
Work Description
No,
T APH - A & B water washing by F/F water done.

2 APH - A & B internal inspection done (T-Bar damaged bolt replaced).

3 APH - A & B duct insulation work done.

4 8.0. 96 gland leakage attended.

5 SB station orifice flange joint D.P. meter. attended.

6 Drum EWLI line RHS side valve replaced [a0 Nb).

7 At Soot Blower Station pressure guage issolating valve replacement done. 3 Nos. valve replaced.

B SB 55 f amming removed & Insulation work done.

9 Boiler door at 55 Mtr. Coil & Door repairing done at LHS & RHS (Refrcatory Pouring)

1_0 All Boiler peep hole - Asbestos rope fitting / sealing done.
11 SB - 59 & its issolating valve gland leakage attended.

T2 Super heater master drain G/L at F/F attended.

13 RO- 62 gland tight done, Actuator lever repositioned.

T4 Spray station SD-9 isolating valve gland leakage attended.

15 SD- 7 & B, RO- 64, S-L47 , L4B, L49,150 gland tight done.

16 FD Fan - A LOP cooler - B valve made free.

17 C/M - G & C ACW Valve famming removal done.

1B C/M- A,E, F, H - P.M. done.

!9 5-145 valve M.S. tR) made operative

2L HRH tR) drain root joint leakage attended.

22 *t (t)t.".*t*-t*.-
23 APH - B steam leakage near SB drain line near pnumatic valve attended

24 C/F - F Service line leakage.(oq+ 'n d . J)

25 LUR reject silo inside accumulated reject removed. (RHS side partial) &bag filter clean.

Executive En neer (BM-II)

 REPORT OF BOTLER TUBE FATLURE AT UNrr NO. 5 (500 MW)
KHAPERKHEDA T.P.S.
DATE.24L2.2015

During Shut down for Boiler validity extension following leakhges observed,
same is attended & hydraulic test carried out The detait is as bellow

Zone - 1st Pass WaterWall Tubes Zone

Location T
1st Pass Front Water Wall Corner No. 4 GH Elevation.

Primary Failure r
1. At 35 Mtr. at W.W. burner panel corner No. 4 (Looking frorn inside
of furnace first tube adjacent to front W.W. panel.

Secondary Failure - 1. At 35 Mtr. starting from burner panel corner No. 4 (Looking from
inside of furnace first tube of front W.W. panel).

Tube Size - 51 X 6 - SAZ 10 Gr. C fWater Wall)

No. of H.P, weld foints I

@4 |oint fPrimary & Secondary)

Unitwithdrawn at I
on Dtd. 22.L2.20L5 at L2:17 Hrs.
Unit clearance given - On dtd. 24.L2.20I5 at 12:35 Hrs.
for Hydraulic Test at
Unit clearance given I
On dtd. 24.L2.20L5 at 20:20 Hrs.
for Boiler Light up at
Outage hours - 56:03 Hrs.
No. of days since last - 25 Month.
Overhaul.
Root Cause of failure - At 35 Mtr. at W.W. burner panel corner No. 4 (Looking from inside of
furnace first tube adjacent to front W.W. panel. Peephole door seal box
to tube weld leakage (Pinhole).
Observation - At 35 Mtr. at W.W. burner panel corner No. 4 (Looking from inside of
furnace first tube adjacent to front W.W. panel. Erection weld joint
leakage & adjacenttube was eroded.

Corfective & - All puncture & worn out tube replaced. Tube Thickness survey
Preventive Action analysis will be carried out during AOH. Sample will be sent'for
metallurgical analysis to detect exact root cause of failure.

A
rl{.1

Executive Engineer (BM-II)

 MAHARASHTRA STATE POWER GENERATION CO. LTD.
KHAPERKHEDA THERMAL POWER STATION
ENCO
Maharashtra State Power Generation Co' Ltd'
(tso 9001:2008, lso 14001:2004 & lso 1800t:20071
Omie of: Chief Engineer, T.P.S., Khaperkheda, Dist. Nagpur, PIN -441102
p hon., (07 1 13 ) iser ge 6 !7 2,z6bzgo, zsg13 1 FAX: 268239(0 ftl | 268t23
(Site) UF.S
@r,ffi
is r nrotnb.r rrf flrO''itff of Sundttd5 iHoio;n$l Ltd,

Reg. No. U-40100 MH 2005 PuC iigOaS Email - cqge,nKR hd@ mflha,ge nco'i 4

i
Date: 2911212015
TURBINE MAINTENAIICB.STAGE.II
UNIT Np. i,q$lJT qowN,RpPgRr

500MW Unit No. 5, TG ser was withdrawn on dated 22/L2/2015

at 12217 hrs. due to boiler tube
Set was sYnchronised on dated 25/L2/20I5 at 04202 hrs,
after carrying out following works at
leakage.
turbine side auxiliaries.

sR. NO. WORKS UAKKItsU UU T

L HP bypass root line gland regulated'

2
ii
cleaning, welding done.
' : : ': ;=:':::;::: ;: qrauls ;:::::;;ttlle
Hpfaater 68 drip manual drain valve replaced with new valve [ul-rbuuJ. tfs orlp
3
choke up removed.
I
qrarn varv' I ePr':rueu-I I a t_

ilgfp-A Conical strainer cleaning & box up done wim new gaSKeE 6t I1s
4
with new one.
I I !

5 fngpp-R turbine casing drain line online clamp removeo & welsmg trone on reaKaBer PuurL'
n PumP mechanical seal filters & coolers cleaning
6
done.
r
seal inlet pipe welomg qone on teaKate Puurt'
I

7 rospp-a main pump NDE mechanical

age from Aux control valve flange
8
atrended. Its metallic CIt-ring lapping done & Flange box up done'
I :-- O L
quplex IIrLers crearrurB t I
o' ut'A uP
f. I

TDBFP A & B MCV & I/H COnVertOr spool, governlng luDe oll
9
done.
1.0 fUgpp-g gland seal Station (meChanical Seal Cooling inleu lme welqmg sQnE on rea,.d't Pu'r'
LI
L2
13 TF
L4 HPH-6A venwalve gland replaced with new one'
15 HPtt{B root valte gland leakage attended.

L6
L7
ed with new one' i

o
1B

L9 ffial taken' Found ok'

done. Valve boxed up. Minual & remote
m-:^l r^l
IrEw uus' I I rcrt krrsu
l_

Primary water pUmp-B alignment done & Coupllng Sploef feplaceo wlul
20
found ok.
2L Cal oit systerfiir side cooler No' 2 cleaned'
ken' No leakages observed'
22
23 trtOf tuUe oil duplex'filters cleaned'
24

Report /SDR-22 -L2-20L5/Page--1

Comp-2 /D:DlOperating Data-12-11-2015/Shut Down
 MAHARASHTRA STATE POWER GENERATION CO. LTD.
/* KHAPERKHEDA THERMAL POWER STATION
ffiHNCO
Maharashtra $bte Power Generation Co. Lld,
(lSO 9001:2008, ISO 14001:2004 & ISO 1800X:2007)
Offce of: Chief Engineer, T.P.S., Khapertheda, Dist. Nagpur, PIN - 441102
P hone : (07 1 13 ) 2681 68 to 77 2,268236, 26813 1 FAX: 268239(0 tfl / 268t23(Site)
@rh$
UFiS ii I marnbar ot.flag,'l' r ct trlndrrdr iHoic;ngr! Ltd.
Reg. No. U-40100 MH 2005 PLC 153548 Email - cegenkpFd@ mahaee4co.in

25 CPU Outlet line root line welding done at leakage point,

26 CEP-C Oil gauge glass leakage attended & oil replaced with new one. Coupling bolts checked.
27 MS to PRDS line root valve gland leakage, HPH-68 root valve gland leakages attended.
28 HPCV-Z val,ve body heating line puncture welding done at leakage point.
Deaeretor start-up vent valve (SMV'22) & actuator replaced with new one. Manual & remote
29
trialtaken found ok.
30 Mill inerting valve gland replaced with new one.

31,
Seal oil system air side DPR adjusted from DP EE/TE 1.53/L.54 to L.72 / L.7L and ring relief
pressure. TE/EE 3.67 / 4.95 to 5.27 / 5.27. W Cmz
EXV-13 checked. Manual operating lever not getting engaged. Valve iamming removed. EXV-13
32
made free for electrical operation.

M. ,t
&u\\e-
Dy.Ex. Addl. Ex. Enginber (TM-II)
":K,!:1f"7
500MW TPS, Khaperkheda 500MW TPS, Khaperkheda

(P$,l*dri re-
Executive Engiheer (TM-II)
500MW TPS, Khaperkheda 500MW TPS, Khaperkheda

Co m p- 2 I D :D / O pe rati n g Data- 1 2- 1 1-20 1 5/S h ut Down Re port /S D R-2 2 -I2-2,0L5 / P aee--Z

 1X5OOMW KHAPERKHEDA TPS

WORK CARRIED OUT BY C&I.II SECTION DURING SHUTDOWN

Date :-22.L2. 201 5 to 2$L2.2AL5

Sr. No. Work done Remarks

L
Coal feeder-H calibration carried out.

2 Coal feeder-E calibration carried out.

3 Oil corner Nozzle valves, ignitor spark and ignitor advance-retract trials
Trial Ok
taken for the purpose of smooth light-up.
4 DRV-5 valve pneumatic connection removed for T/M work, connection
Trial Ok
restroed after T/M work,, valve calibration carried out valve trial taken.
5 FD-FAN-A vane Air supply pressure regulator replaced by new one, vane
Trial Ok
tria I ta ke n.
6
HPSV-L close feedback limit switch adjustment carried out.

7 LPBP-I Stop valve limit switch mounting plate was dislocated from its
loction,plate welding carried out by T/M ,limit switches adjusted , trial Trial Ok
ta ke n.

8 HBPE-L valve servovalve cleaned, oil filter on oil supply line replaced.All
Trial Ok
HP bypass valve trial taken.
9 HP Bypass oil supply unit-l filter oil leakage attended.
10 Air Heater-A & B air motor solenoid checked & solenoid trial taken. Trial Ok
LL TDBFP-A EHTC primary DPU replaced, DPU changeover from primary to
Trial Ok
secondary & secondary to primary trial taken.
L2 TDBFP-A oil pressure transmitter oil leakage attended.

13
ESP Hopper Ash level high sensors
\,,/ DIH4,A4H3 was da maged
A1 H3,A1 H2,A2H8,A3 H4,BLH4,B2 H6, 83 H5,

/jam.These sensors removed , replaced by new one & controllers tuned.

L4 ESP hopper C & D pass Ash level high sensors checked. found OK.
15 ESP hopper B pass Ash high level sensors checked. found OK.
L6 ESP hopperA pass Ash high level sensors checked. found OK.
L7
AHP PLC panel power supply checking work.

18
L2 channel recorder installed at FOPH for monitoring the parameters.

L9 Fresh brine weak storage tank-l level switch replaced.

(o
zelb
EE ( C&t-il
 1x500MW Khaperkheda TPS

Works carried out by TEST-ll Section during Shutdown

Date 22.L2.15 to 25.t2.2015

SN Works carried out Remarks

Boiler MCCa/C L,2 & B/C:- Control Ckt. Modification and Protection
L Trial OK.
relay logic modification done.
A Pass B/S -2Outlet Gate:- DOL modified JB installed &
2 Trial OK.
commissioned. Limit setting done.
B Pass B/S-1 and B/S-2 lnlet and Outlet Gate :-Close and open limit
3 Trial OK.
switch setting done.

4 C Pass B/S-1 lnlet Gate:-Close and open limit switch setting done. Trial OK.

D Pass B/S-1 and B/S-2 lnlet and Outlet Gate:-Close and open limit
5 Trial OK.
switch setting done.
6 C Pass B/S-2 Field No.5 and 8:- OCC Test carried out Trial OK.
7 WWSB No.55:- Control circuit checked and trial taken. Trial OK.
8 SMV 22:- New actuator mounted and limit switch setting done. Trial OK.

9 SOP 1 & 2 :-Current Transducer connection done at CRE Panel. Trial OK.
 $OO"Srw l{hffitsrlrhe da HPs
Work cat'riecl t:ut 1:y* HM-II cluring shut dollt.
Ilat e : 22.12,20 I 5 to 24 ,12 .2{} 1 5

Remark
Cornptrctcd..

iclclne.
i
I

i ilSeal Air Fem #A Motor

l

I iilHPCF Pnmp lVlotor # A

i

i iiilvacuunl }\rrrlp #A lvlotor

1

i
:l
:t
livlPrimaryWater# R l\,fotcr
i I ..r A ,.-r r-t -, ... AI Y'1 rr 1r'-
i I vlAC $canner Air: Fnr.r Motr:r
r

ii'I2\ I prevent-ive rn*ir:tenance nf foltrowing f"tT mct*r i

!
Cr:mpleteci.
tt
tt

l{a
i

i clane,
ilPA lan tr:r: -A fk B
i
i
',t
I
iil Fn Fan Mr:l*r *A tk B
iii) I\{DBFP h4ator
ir') trlf Fan fu'trctr;r 5A 8s 5ts

tlerreratr;r IIT Cubicie in,Spectian atrd .r:leaning Completr:cl.

ot" R,Y*R Phase rlone and B Phase V'T-2
repk*ceri v,,'it.h n{:rl,' o;rc.

(}T- R Plrase f{acliator bank oil leakage fartially

altenttred "

L{
Executive Bngintr !nnA-U1