NTPC/VINDHYACHAL

UNIT OVERHAULS
6X210 MW & 4X500 MW UNITS
OF

VINDHYACHAL SUPER THERMAL POWER PROJECT,

NATIOANAL THERMAL POWER CORPORATION LTD.,
P.O. : VINDHYANAGAR, DISTT.: SIDHI (M.P.), PIN:486885
NTPC/VINDHYACHAL
UNIT OVERHAULS PHILOSOPHY
210 MW ( LMW ) UNITS

TYPE OF OVERHAUL MAIN AREAS IDENTIFIED PERIOD OF FREQUENCY

FOR OVERHAUL OVERHAUL
“A” BOILER & AUX. 20 DAYS EVERY YEAR
TUR. BRGS. INSP.
“X” BOILER & AUX. 21 DAYS EVERY 3rd YEAR
GENERATOR ROTOR THREAD OUT
“D” BOILER & AUX. 35 DAYS EVERY 6th YEAR
ALL TURBINE CYLINDERS O/H
GENERATOR ROTOR THREAD OUT
NTPC/VINDHYACHAL
UNIT OVERHAULS PHILOSOPHY
500 MW ( KWU ) UNITS

TYPE OF OVERHAUL MAIN AREAS IDENTIFIED PERIOD OF FREQUENCY

FOR OVERHAUL OVERHAUL
“E” BOILER & AUX. 15 DAYS EVERY YEAR
TUR. BRGS. INSPECTION

“F” BOILER & AUX. 25 DAYS EVERY 3rd YEAR

LP TURBINE INSPECTION

“G” BOILER & AUX. 35 DAYS EVERY 8th YEAR

HPT / IPT O/H
GENERATOR ROTOR THREAD OUT
NTPC/VINDHYACHAL

UNIT OVERHAULS - PHILOSOPHY

210 MW ( LMZ ) UNITS

 TO CONTROL THE O&M COST FOLLOWING ARE THE ACTIONS:

 SEQUENCE OF O/H FOR THE STATION ARE SO ADJUSTED

THAT NOT MORE THAN TWO MAJOR O/Hs (TYPE “D”)
TAKEN UP IN A YEAR.

 WHENEVER TWO MAJOR O/H COMMENCES IN A STATION

IN A YEAR, SITE TAKES DECISION, DEPENDING ON BOILER
CONDITIONS, TO RESTRICT THE O/H DURATION OF BOILER
SUITABLY TO 17 DAYS AND 15 DAYS FOR 200 MW AND 500
MW UNITS RESPECTIVELY.
NTPC/VINDHYACHAL
OBJECTIVES OF UNIT OVERHAULS

• TO MAXIMIZE PLANT AVAILABILITY

• TO MINIMIZE MAINTENANCE COST THROUGH

OPTIMIZATION OF RESOURCE UTILIZATION

• TO CREATE SAFETY IN WORK, EQUIPMENT AND

ENVIRONMENT
NTPC/VINDHYACHAL

AIMS OF UNITS OVERHAUL

• TO IMPROVE AVAILABILITY OF EQUIPMENT & SYSTEM

• TO IMPROVE QUALITY & INSPECTION OF MAINTENANCE JOBS
• TO IMPROVE MONITORING & REPORTING OF O/H PROGRESS
• TO REDUCE OVERHAUL DURATION
• TO IMPROVE THE RE-COMMISSIONING INTERFACE
• TO PROVIDE A RECORD OF WORK CARRIED OUT
• TO MINIMIZE ISOLATION RESTRICTIONS
• TO REDUCE DUPLICATION OF ENGINEERING EFFORTS
• TO ENSURE STATUTORY REQUIREMENT OF BOILER LICENCE
NTPC/VINDHYACHAL
CATEGORIZATION OF
UNIT OVERHAUL PROCESS

 PLANNING
 UNIT SHUT DOWN
 COOLING DOWN OF MACHINES
 DISMANTLING
 INSPECTION FOR CONDITION
 REPAIR & RECTIFICATION
 ASSEMBLY
 TESTING & INSPECTION
 REVIVAL OF EQUIPMENT & SYSTEM
 REVIVAL & RECOMMISSIONING OF UNIT
NTPC/VINDHYACHAL

IMPROVEMENT AREAS IDENTIFIED

• BARRING GEAR STOPPAGE TIME

• CONDENSER VACUUM
• GENERATOR AIR TIGHTNESS TEST TIME
• AIR INGRESS IN BOILER
• SCOPE OF WORK OF GENERATOR OVERHAUL
• ELECTRICAL TESTING TIME
• REVIVAL TIME OF UNIT AFTER UNIT OVERHAUL-HFO
CONSUMPTION
• SCOPE OF IN SITU TESTS DURING UNIT OVERHAUL
• SCAFFOLDING ERECTION & DISMANTLING TIME
• PERCENTAGE AREA OF TUBES COVERED FOR D-METERING
• BOILER SAFETY VALVES SETTING TIME

ULTIMATELY LEADING TO IMPROVEMENT IN PLANT

AVAILABILITY, RELIABILITY & REDUCTION OF O&M COST
NTPC/VINDHYACHAL

PLANNING OF UNIT OVERHAULS

NTPC/VINDHYACHAL

CLASSIFICATION OF PLANNING ACTIVITIES

 PRE OVERHAUL ACTIVITIES

 DURING OVERHAUL ACTIVITIES

 POST OVERHAUL ACTIVITIES

 NTPC/VINDHYACHAL

PRE OVERHAUL ACTIVITIES

 PLANNING & APPROVAL OF EIGHT YEAR ROLLING PLAN

OF UNIT OVERHAULS
 PLANNING & APPROVAL OF NEXT FINANCIAL YEAR PLAN
FOR UNIT OVERHAULS
 PLANNING & APPROVAL OF MAJOR WORKS TO BE
CARRIED OUT DURING UNIT OVERHAULS
 IDENTIFICATION, REQUIRED QUANTITY PROJECTION
AND REVIEW OF STATUS OF CONSUMABLES ( STOCK
ITEMS) ON MONTHLY BASIS FOR UNIT OVERHAULS
 NTPC/VINDHYACHAL

CONTD…
 IDENTIFICATION OF CRITICAL MATERIALS REQUIRED
FOR UNIT OVERHAULS AND REVIEW ON MONTHLY BASIS.
 PREOVERHAUL MEETING FOR REVIEW OF CONSTRAINTS
& PREPAREDNESS INVOLVING ALL.
 PRE OVERHAUL CONDITION MONITORING REPORT
 PREOVERHAUL UNIT SURVEY
 UNIT OUTAGE ANALYSIS FROM LAST OVERHAUL
 FEED BACK OF UNIT FROM FIRST SYNCHRONIZATION
 REVIEW OF STATUS & COORDINATION OF WELDING
SUPPLY, LIGHTING, LIFTS, HOISTS, CRANES ETC.
 NTPC/VINDHYACHAL

CONTD…
 PAST OVERHAULS AT A GLANCE (HISTORY OF UNITS)
 PREPARATION OF MILESTONES (PLANNED)
 COMPILATION OF UNIT DEFECT LIST

 PRE OVERHAUL SPRAY VALVES CHARACTERISTICS

WORK REQUIRED TO BE CARRIED OUT AS PER

 OPERATION REQUIREMENT
 EFFICIENCY REQUIREMENT
 CHEMISTRY REQUIREMENT
 TRIPPING COMMITTEE RECOMMENDATIONS
 C&I REQUIREMENT
 NTPC/VINDHYACHAL

CONTD…
 BOILER TUBE LEAKAGE COMMITTEE RECOMMENDATIONS
 OS RECOMMENDATIONS
 CONDITION MONITORING GROUP RECOMMENDATIONS
 SAFETY REQUIREMENT
 R&M REQUIREMENT

 PREPARATION OF:
 PTW & CLEARANCE BOOKS FOR BOILER & AUX.
 PTW & CLEARANCE BOOKS FOR TG & AUX.
 CLEARANCE & RECOMMISSIONING BOOK FOR VALVES,
DAMPERS, IGVs, SOOT BLOWERS & LRSBS
 NTPC/VINDHYACHAL

 CONTD...
 CHECK SHEET FOR MOTOR TRIALS, EQUIPMENT
RECOMMISSIONING & PROTECTION CHECKING
 CHECK SHEET FOR VALVES REQUIRED FOR CONDENSER
FLOOD TEST
 CHECK SHEET FOR VALVES REQUIRED FOR BOILER
HYDRO TEST

 COMMUNICATION LOG BOOK

 NTPC/VINDHYACHAL

DURING OVERHAUL ACTIVITIES

 PREPARATION OF DISPLAY BOARD FOR

COMMUNICATION OF OVERHAUL PLANNING

 COORDINATION IN ISSUE OF PERMITS

 MONITORING OF WORK PROGRESS / COMPLETION

 COORDINATION OF REGULAR UNIT OVERHAUL MEETING

AT 5:30 PM IN O&M CONFERENCE HALL

 PREPARATION & DISTRIBUTION OF RECORD NOTES

 FEEDBACK TO WRHQ & CC-OS FOR WORK PROGRESS

NTPC/VINDHYACHAL

 MONITORING & REVIEW OF CRITICAL VALVES STATUS AS

PER CHECK SHEETS REQUIRED FOR CONDENSER FLOOD
TEST & BOILER HYDRO TEST
 MONITORING & REVIEW OF CLEARANCES AVAILABLE &
RECOMMISSIONING PROGRESS ( MOTORS TRIALS /
EQUIPMENT TRIALS)
 COORDINATION IN
 FURNACE AIR TIGHTNESS TESTS
 CONDENSER FLOOD TESTS
 BOILER HYDRO TESTS
NTPC/VINDHYACHAL

POST OVERHAUL ACTIVITIES

 PREPARATION OF UNIT-WISE UNIT OVERHAUL REPORT
IN BOOK FORM HARD COPY FOR LIBRARY & ISO

 PREPARATION OF UNIT OVERHAUL REPORT IN CD-

FORMAT

 POST OVERHAUL REVIEW OF WORKS PLANNED AND

ACTUALLY COMPLETED.

 POST OVERHAUL REVIEW OF IMPROVEMENT IN

PARAMETERS & EFFICIENCY
 POST OVERHAUL PLAN Vs ACTUAL DEVIATION SHEET
NTPC/VINDHYACHAL

PROCESS IMPROVEMENTS
• BOILER EXTERNAL WATER WASHING WAS CAUSING
DAMAGE TO INSULATION AND DELAY IN START OF
OVERHAUL ACTIVITIES, DRY BOILER CLEANING
STARTED.
• QUICK ERECT SCAFFOLDING IS BEING USED FOR BOILER
INTERNAL CLEANING & INSPECTION
• HIGH PRESSURE WATER JET CLEANING IS BEING DONE
FOR BOILER TUBES
• ALL PA FANS & MILL MOTORS VIBRATION MEASUREMENT
ALSO STARTED DURING UNIT OVERHAULS
• ALL HT MOTORS TRIAL RUN IS BEING TAKEN FOR 8 HRS
AND LT MOTORS FOR 4 HRS
NTPC/VINDHYACHAL

PROCESS IMPROVEMENTS

• CONDENSER TUBE CLEANING IS BEING DONE USING

CONCO BULLETS
• INVOLVEMENT OF FQA IS INCREASED IN MAIN TURBINE &
GENERATOR AREA
• BOILER DRUM FILLING USING HOT WATER STARTED
• BOILER TUBES D-METERING SCOPE INCREASED UPTO
25000 LOCATIONS.

• 24-VOLT HAND LAMPS ARE BEING USED

• PREOVERHAUL / DURING OVERHAUL SAFETY SURVEY
BEING CARRIED OUT
NTPC/VINDHYACHAL

ADDITIONAL RESPONSIBILITIES

• DRAWING SECTION: O&M DRAWING SECTION IS PIONEER

IN DEVELOPMENT OF DRAWINGS IN AUTO CAD.
MANPOWER : TWO DRAFTMENTRAINED IN AUTO-CAD
• PRINT ROOM: O&M PRINT ROOM COPE UP THE DAY TO
DAY REQUIREMENT OF
PHOTCOPYING, CYCLOSTYLLING & AMMONIA PRINTING
OF DRAWINGS REQUIRED FOR INDENTING PURPOSES.
MANPOWER: ONE ATTENDANT
• DISPLAY ROOM: O&M DISPLAY ROOM LOCATED AT
SERVICE BUILDING “O” MR IS BEING MAINTAINED AND
UPDATED REGULARLY
NTPC/VINDHYACHAL LONG TERM PLANNING

CONSTRAINTS
• UNIT OVERHAUL REPORTS: INSPITEOF ALL BEST POSSIBLE
EFFORTS, PROBLEM IS BEING FACED TO GET THE FEEDBACK
FROM OTHER DEPARTMENTS FOR THE JOBS COMPLETED,
MEASUREMENTS TAKEN AND EXPENDITURE INCURRED
DURING UNIT OVERHAULS, WHICHCAUSES DELAY IN
COMPILATION OF UNIT OVERHAUL REPORTS.

• OVERHAUL COST: PRESENTLY IT IS DIFFICULT TO GET THE

FINANCIAL DATA i. e. UNIT OVERHAULS COST (THE
EXPENDITURE INCURRED DURING RESPECTIVE UNIT
OVERHAULS). CONTINUOUSLY THESE DATA ARE BEING
ASKED BY CC & WR.
• ISSUE OF MATERIALS: MATERIALS PROCURRED FOR UNIT
OVERHAULS MUST BE TAGGED BY STORES AND NOT TO BE
ISSUED TO ANY OTHER DEPARTMENT WITHOUT CONSENT.
NTPC/VINDHYACHAL

THANK YOU