Action Plan for Prevention of Flame Failure

Sr #
D

Issue
Mill Finess

#
1

Actions
70%>200 Mesh/Retention 1%<50 Mesh

1.b Proper Scanner Air Pressure E Scanner Heathiness 1.c F CHP/Mill healthiness 3 Healthiness of scanner cooling air hoses & guide pipes Adherance to PM of pulverized system

Soot blowing System

Oil Support

1 Proper soot blowing pressure to be ensured after every overhaul by pressure setting 3 Healthiness of LRSBs to be ensured 3 Gun Cleaning to be done as per schedule 4 Oil filter cleaning to be done regularly

Measures in place
Roll/Ring gap adjustment Spring Pressures checking/adjustment Roll wear monitoring Classifier adjustment Cleaning of Filters Fan O/H outage Inspection during overhaul/ replacement if necessary Mill PM Feeder PM Ongoing; sootblower nozzle alignment checks during overhaul Ongoing Being done as per operations requirement Ongoing

Remarks
IN PM Replace if more IN PM

IN PM IN PM IN PM

Action Plan for Prevention of Clinkering & Ash Build up

Sr #
E Burner Tilt 1 F Mill fineness 3 Regular preventive maintenance to be done to maintain mill fineness within limits G Soot blowing System Coal Burner Healthiness 2 Proper soot blowing pressure to be ensured after every overhaul by pressure setting 4 Healthiness of LRSBs to be ensured Eroded coal nozzles/tips to be replaced during 1 opportunity shutdowns After overhauling boiler/maintenance of 1 furnace, the boiler should be inspected and loose material if any should be removed from furnace/bottom ash hopper Chemical injection (Polarchem) to help reduce 2 formation of clinkers by preventing fusion of ash particles Availability of all ash discharge lines with adequate HP pressure (for hydro ejector system) and scrapper conveyors (Continuous 5 De-ashing system),Clinker grinders, hopper gates, flushing nozzles shall be ensured through regular PM

Issue

#
3

Actions

In case of shear pin breakage it shall be attended at the earliest opportunity and operation of burner 70%>200 Mesh/Retention 1%<50 Mesh

Other operational measures

Ash build up preventative measures

Measures in place

Remarks
In case of jamming of tilt assembly due to clinkering or deformation of burner compartments, the same shall be attended at the earliest outage opportunity IN PM Replace if more

Being attended at the earliest Roll/Ring gap adjustment Spring Pressures checking/adjustment Roll wear monitoring Classifier adjustment

On going Ongoing; sootblower nozzle alignment checks during overhaul Ongoing Planned for major overhauls

IN PM IN PM Needs study in view of our congested burner configuration

On going

Inspection of furnace done before boxing up

On going

On going

IN PM

Action Plan for Reduction of Boiler Tube leakage (BTL)

Area
General Stringent Test of HP Welders

Action Plan

Avoid Gas cutting of tubes Proper Edge Preparation Proper Storage of Tubes Improvement of radiography quality S- Panel Inspection & DP of attachments during overhaul Through cleaning of S-panels. S-panels bottom, and side wall 90 deg bends by HP jet pump Thickness survey of S-Panel Checking of field welds/replacement Deformed tubes Thermal expansion/constraints and checking DP checking/inspection of Dead Chamber Seal trough DP of attachments attachment & Replacement of affected tubes Scallop bar Providing new scallop bars & protection plates Erosion Failures Replacement of eroded tubes Sheilding of tubes Wire mesh protection for end coils Eco weld joint 100% radiography failure Supervision during joint preparation & fit up Eco erection weld joint failure

Radiography of old joints and rectification if any Procurement of new coils with 100% weld joint radiography

Hardness testing of tubes Platen SH bend Inspection of supports Replacement of affected tubes & bends Inspection of wrapper tubes & intersections Reheater Extensive thickness survey & dimensional check Inspedtion of DMW joints DPT of safe end tubes Metallography of tube material to asses creep damage Reheater Tie up lug up attachment Inspection of fluid cooled spacer tubes & attachments Extensive thickness survey & dimensional check Replacement of eroded tubes Burner zone Inspection of bends in Diamond panels Cutting tubes samples in high heat zones for analysis

Economizer

Platen Roof

LTSH Water wall (Spiral & Vertical) Superheater

Thickness survey of upper economizer & inspection (SCW) Thick ness survey of eroded bends & replacement Replacement of erosion sheilds Inspection Eco inlet header stubs for FAC Inspection of baffles, replacement of eroded & damaged sections Replacement of eroded and mis-aligned tubes Visual inspection of tubes in HRSB/LRSB areas Inspection of attachments Inspection of coil supports Radiography of old erection joints and rectification if any Replacement of eroded tubes and bends Replacement of erosion sheilds Visual inspection of tubes in HRSB/LRSB areas Extensive tube thickness / replacement of eroded tubes Radiography of old erection joints and rectification if any Inspection of Transition header - thickness survey DP of attachments Thickness survey DP of DMW joints

Riser/Sat.Steam /Supply pipes Radiography of old joints DP of vents/drain stubs Drains/Vents DP of socket welded joints in piping Replacement of piping based on thickness survey Power cycle piping Removal impulseof line insulationn & DP checking Thickness survey & replacements if any Hangar Tubes Replacement of damaged erosion sheilds Roof tubes Inspection of tubes Seal plates/EJ Inspection, repair if any Pent House Inspection of headers (non insulated) Inspection of vents & supports - repairs if any Boroscopy of Headers Handers Comparision of Hot & Cold settings Replacement of Broken tie rods Chemistry Water & steam cycle parameters maintained limits

Measures
IBR Certification CGPL Quality Certification Not in WI for BTL Inspection by Quality Done by stores as per guidelines Numbering of joints

Replacement/rebuid Inspection/DP of hanger supports

As per inspection As per inspection Not considered at present Part of WI for BTL Part of WI for BTL

As per inspection Not considered at present

Replacement if any indication is found

Based on inspection

Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection

Based on inspection

Based on inspection Based on inspection Based on inspection Based on inspection Based on inspection Correct if any Based on inspection Based on inspection

Remarks

All pressure parts are cut by low heat input method Wherever possible edge prepartion done on lathe with proper angles Adequate preventive measures to ensure weld quality 100% DP of attachment welds HP washing covered in outage scope Extensive thickness survey/LFET planned In inspection plan based on inspection In inspection plan In inspection plan In inspection plan In inspection plan In inspection plan

No erosion as per findings during short outages

In inspection plan

In inspection plan In inspection plan In inspection plan In inspection plan In inspection plan based on findings In inspection plan based on findings In inspection plan based on findings In inspection plan based on findings

In inspection plan In inspection plan In inspection plan In inspection plan

In inspection plan In inspection plan In inspection plan In inspection plan In inspection plan In inspection plan

In inspection plan In inspection plan LFET planned

on sample basis in inspection plan in inspection plan in inspection plan in inspection plan in inspection plan in inspection plan in inspection plan in inspection plan

Optional - if required Compare with readings at time of commissioning