10.

0 TUBE LEAKAGE ANALYSIS Contents:

10.1 TREND OF BOILER TUBE LEAKAGE FOR THE LAST 5 FIN. YEARS 10.2 TUBE LEAKAGE WITHIN 3 MONTHS OF OVERHAUL-CURRENT FINANCIAL YEAR 10.10 AVERAGE MILL ROLL LIFE (In Hrs.)

10.1 TREND OF BOILER TUBE LEAKAGE FOR THE LAST 5 FIN. YEARS
Current FY till Date 3 0.62

2001-02 Tube Lekage (No.) Tube Lekage (%)

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

4 0.84

5 0.66

10 1.58

8 1.05

5 0.49

6 0.59

13 1.23

16 1.36

10.2 TUBE LEAKAGE CURRENT FINANCIAL YEAR Tube leakage with in 3 months from date of Ovehaul are marked red

Sl No

Unit

Unit wise Cmulative

Date

Location

Primary cause

Outage hrs

Outage %

1 2 3

1 2 3 1 5/25/09 Economiser Flue Gas Errosion 49.65 0.27

4 4 5 6 2

4/14/09 4/28/09

LTSH Steam Cooled Wall Tube

Flue Gas Errosion Flue Gas Errosion

26.87 37.48

0.15 0.20

10.3 EXCEPTIONS OF THE ACTION PLAN OF LAST FINANCIAL YEAR:

Final Recommendation by Central Committee for Boiler Tube Leak reduction

S.N

Unit

Outage No./Date

Location

Root Cause

Action Plan

NIL

10.4 SAFETY VALVE AVAILABILITY STATUS

Sl No 1 2 Unit 1 2 Description
all Safety Valve available all Safety Valve available

Non Available Reason since (date) N.A N.A

Action plan

Target Date

Responsib ility

all Safety Valve available Except HRH ERV Left

all Safety Valve available

06.07.2009

To be passing.(Including manual isolating attended in valve) next unit shutdown.

Sept'09

BMD

N.A

all Safety Valve available (MS ERV RHS)

05.08.09

To be ERV Passing/Isolating valve S041& attended in Next S042 also passing next unit opportunity shutdown.

BMD

10.5 METAL TEMPERATURE EXCURSION

(Based on Metal temp. excursion log / Daily Log*) Limit Value (oC)

Area

Unit-1

Unit-2

Unit-3

Unit-4

Unit-5

Unit-6

Unit-7

WW

NP

NP

NP

NP

NP

NP

SH Max. temp. during excursion-(oC) RH

580(stgI),580(stgII),602(stg-III) 570(unit1),550(unit2),620(stgII),623(stg-III) 580(stgI),580(stgII),570(stg-III) 480(stgI),480(stgII),455(stg-III) -

--

Nil

Nil

Nil

Nil

--

Nil

Nil

Nil

Nil

Platen SH

--

Nil

Nil

Nil

Nil

LTSH WW Duration for which temp. exceeded the limit (hrs.)

--

Nil -

Nil -

Nil -

Nil -

Duration for which SH temp. RH exceeded the limit (hrs.) Platen SH LTSH

*Note: ORT Cordinator to check the above aspects personally

No. of days

153

TREND OF BOILER TUBE LKG FOR LAS

No./%

Prev FY SAME PERIOD 5 1.12

DATA TABLE

20 15 10
10 4 5

5 0

0.84
2001-02

0.66
2002-03

1.58
2003-04

Cumulative hrs

Cumulati ve %

49.65

0.27

64.35

0.09

Responsibility

Target Date

Present Status

Remark

Unit-2 system under commissioning. Modified Card form Yokogava Bangalore received at site. Work will be competed during Unit-2 S/D .(oct.'09).

--do--

--do--

--do--

UBE LKG FOR LAST 7 FIN. YR

Tube Lekage (No.) Tube Lekage (%)

april 16

may

june

july

august

sept

octobet

november

13

8
5

4 2.08

5 1.77

6 1.65

6 1.32

8 1.43

9 1.25

10 1.22

1.58

1.05
2004-05

0.49
2005-06

0.59
2006-07

1.23
2007-08

1.4 1.36

003-04

2008-09

december january

february

march

13 1.33

16 1.37

16 1.2

19 1.32

10.10 AVERAGE MILL ROLL LIFE (In Hrs.)

APRIL 08 MILL ROLL/LINER TYPES Stage-I: May'08 MILL ROLL/LINER TYPES

AVG. LIFE

AVG. LIFE 6658 HRS

High Cr. (MPSP) 6700 High Cr. (MPSP) Grinding Rolls (Guarenteed life) Grinding Rolls

MILLS [BBD4760] HI-CHROME LINERS Stage-II: High Cr. (MPSP) Grinding Rolls

41111.67 Mill-4-CD : 39112 Hrs. MILLS [BBD-4760] Mill-3-CD : HI-CHROME 38568 Hrs. LINERS Mill-3-AB : 45655 Hrs.

41111.67 Mill-4-CD : 39112 Hrs. Mill-3-CD : 38568 Hrs. Mill-3-AB : 45655 Hrs.

6029

Stage-III:

High Cr. (MPSP) Grinding Rolls

5770 HRS

Jun-2009 MILL ROLL/LINER TYPES High Cr. (MPSP) Grinding Rolls

Jul-2009 MILL ROLL/LINER TYPES High Cr. (MPSP) Grinding Rolls

Aug-2009 MILL ROLL/LINER TYPES High Cr. (MPSP) Grinding Rolls

AVG. LIFE 6729 Hrs. 41111.67 Mill-4-CD : 39112 Hrs. Mill-4AB : 44445 hrs. Mill-3-CD : 38568 Hrs. Mill-3-AB : 45655 Hrs. 5968 Hrs.

AVG. LIFE 6729 Hrs. 41111.67 Mill-4-CD : 39112 Hrs. Mill-4AB : 44445 hrs. Mill-3-CD : 38568 Hrs. Mill-3-AB : 45655 Hrs. 5806 Hrs.

MILLS [BBD4760] HI-CHROME LINERS

MILLS [BBD4760] HI-CHROME LINERS

MILLS [BBD4760] HI-CHROME LINERS

High Cr. (MPSP) Grinding Rolls

High Cr. (MPSP) Grinding Rolls

High Cr. (MPSP) Grinding Rolls

Aug-2009 MILL ROLL/LINER TYPES

8-Sep

OCTOBER'08 MILL ROLL/LINER TYPES

AVG. LIFE 6729 Hrs. 41111.67 Mill-4-CD : 39112 Hrs. Mill-4AB : 44445 hrs. Mill-3-CD : 38568 Hrs. Mill-3-AB : 45655 Hrs. 5963 Hrs.

AVG. LIFE

OCTOBER'08

NOVEMBSER 08 MILL ROLL/LINER TYPES AVG. LIFE

DECEMBDER'09 MILL ROLL/LINER TYPES AVG. LIFE MILL ROLL/LINER TYPES

AVG. LIFE

AVG. LIFE

MILL ROLL/LINER TYPES

AVG. LIFE

MILL ROLL/LINER TYPES

AVG. LIFE