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COS-ISO-00-OGN/OPS/MECH/031

Rev. No.: 0 March, 2000

OPERATION GUIDANCE NOTE

CARE AND MAINTENANCE OFTURBINE PLANT FEED SYSTEM

OPERATION SERVICES DIVISION

National Thermal Power Corporation Ltd

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NATIONAL THERMAL POWER CORPORATION

OPERATION AND MAINTENANCE FORMAL DOCUMENTATION SYSTEM

OPERATION GUIDANCE NOTE: COS-ISO-00-OGN/OPS/MECH/031

Rev. No.: 0 D!e: M"#$% &000

CARE AND MAINTENANCE OFTURBINE PLANT FEED SYSTEM

Approved forImplementation by ..

Director (peration!

Date: ..

"n#$irie% to : &ead of 'orp. peration ervice%

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CARE AND MAINTENANCE OF TURBINE PLANTFEED SYSTEM

INDE'

SNo Content! Pa"e No

1.0 INTRODUCTION )

&.0 SUPERSEDED DOCUMENTS )

3.0 RECORDS OF FEED SYSTEM STATUS )*.) b+ective )*.2 Information Re#$ired )

(.0 ENGINEERING ASPECTS OF PLANT OPERATION *.) b+ective% *.2 -he Infl$ence of peratin 'ondition on

'omponent /ife .* "%%ential rotection for ther lant 1rom

1a$lt% riinatin in the 1eed y%tem . Re#$ired Monitorin In%tr$mentation 3. Interim Arranement% 3.3 peratin /imit% 3

).0 PLANT MAINTENANCE AND MODIFICATION 4.) b+ective% 4.2 lanned Maintenance Activitie% 4.* reventive Maintenance 5. Modification% 5

*.0 LIFE ASSESSMENT 53.) b+ective% 53.2 '$m$lative -$be 1ail$re 53.* 'rac6 7ro8th and -hermal 1ati$e 93. In%pection roced$re% )0

+.0 REVIEW )0

APPENDI'

A. Definition of tart 'ateorie% ))) 1ormat of -$rbine 1eed y%tem tat$% Record% )22 1eed y%tem tat$% Record )** perational &i%tory ) In%pection ; Maintenance ) R$nnin Record% )3

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COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0Care and Maintenance of !r"ine P#ant $eed S%&te'

CARE & MAINTENANCE OF TURBINE PLANT FEED SYSTEM

1. INTRODUCTION

(e feed &%&te' i& defined a& t(e co')#ete feed *ater (eating train+ inc#!ding

a## &tage& of feed (eating+ a&&ociated conden&ate and feed )i)e*or, and

va#ve&+ "#ed &tea' )i)e*or, and va#ve&+ drain )i)e*or,+ va#ve& and receiver&"!t ec#!ding t(e 'ain )!')ing !nit& and t(eir re&)ective drive& e.g.

conden&ate etraction )!')&+ dri) )!')& and "oi#er feed )!')&.

$or t(e )!r)o&e& of t(i& doc!'ent+ t(e feed (eater& c!rrent#% in &ervice *i## "e

&!"-divided into t(ree gro!)&:

i o* )re&&!reP (eater&+ &!rface t%)eii eaerator&

iii Hig( )re&&!reHP (eater&+ &!rface t%)e

(i& G!idance Note reco''end& )roced!re& intended to ac(ieve re#ia"#e feed

&%&te' o)eration and to 'ini'i&e t(e &%&te' *(o#e #ife co&t& "%:

i E&ta"#i&(ing t(e )edigree(i&tor% and recording t(e &tat!& of

co')onent& &o a& to )rovide a "a&i& for a&&e&&ing t(eir f!t!re

ca)a"i#it%.

ii O)ti'i&ing o)erating condition& and t(ere"% 'ini'i&ing t(e rate ofco')onent deterioration.

iii eter'ining t(e rate of co')onent deterioration &o t(at an% re'edia#

action re2!ired to ac(ieve o)erating target& can "e i')#e'ented on a)#anned "a&i& at t(e o)ti'!' ti'e.

iv En&!ring t(at ro!tine 'aintenance and an% re'edia# action e')#o%ed

give t(e greate&t overa## "enefit.

2. SUPERSEDED DOCUMENTS

Ni#

3. RECORDS OF FEED SYSTEM STATUS

3.1 Objective

(e o"ective i& to )rovide a data"a&e for f!t!re engineering !)grade&.

3.2 In!"#$ti!n Re%i"e'

(e co')re(en&ive #i&t )re&ented in &!"-&ection 3.4.1 to 3.4.5 inc#!&ive "e#o*

identifie& a## of t(e data t(at 'a% "e re2!ired to a&&e&& t(e &tat!& of a feed

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&%&te'. 6 data"a&e &(o!#d "e &e#ected fro' t(i& #i&t (aving d!e regard to t(e

#eve# of infor'ation avai#a"#e fro' 'an!fact!rer& for eac( individ!a# &%&te'.

3.2.1 O"i(in$) De*i(n Intent

i Heater t%)e&

ii iagra''atic arrange'ent of feed &%&te'

iii 7a#ve &c(ed!#e

iv Genera# arrange'ent& of eac( (eater

v etai# arrange'ent& of :

a Heater &(e##&inc#!ding &!))ort& and "o#ting" !"e ne&t& inc#!ding "aff#e&+ &(ro!d&+ etc.

c !"e )#ate&/(eater& inc#!ding t!"e fiing&

d 8ater"o/divi&ion )#ate

e eaerating (ead/tra%*or, and/or &)ra% no99#e detai#&f #ed &tea' )i)e*or,

g Conden&ate/feed )i)e*or,( rainage )i)e*or,inc#!ding orifice& if fitted

i rain& receiver&

Pre&&!re re#ief va#ve ca)acitie& and &etting&

, ;!a#it% #i'it& for )i)e*or, "end&

vi O)erating condition& for eac( &tage inc#!ding ta))ing )oint& and

condition& for "#ed &tea'.vii Reco''ended rate& of te')erat!re c(ange acro&& (eav% &ection&.

3.2.2 M!'iic$ti!n t! O"i(in$) De*i(n

Inc#!de detai#&+ *it( f!## &!))orting dra*ing&+ of a## 'aor 'odification& to

t(e origina# de&ign e.g. )i)e*or,/va#ve 'odification&+ additiona# va#ve&+ "a&icde&ign c(ange& to t(e (eater& t(e'&e#ve&+ 'et(od& of de&!)er(eating+ drain&

coo#ing+ ro!ting of drainage etc.

8(ere 'odification& to t(e Contro# and Protection S%&te' invo#ve

'odification& to (ard*are t(e&e &(o!#d a#&o "e recorded.

3.2.3 M$n$ct"in( in!"#$ti!n

Materia# &)ecifiction& for :

i Heater &(e##&/t!"e)#ate&/(eader&

ii !"e&

iii Conden&ate / feed )i)e*or,

iv #ed &tea' )i)e*or,

v 7a#ve&


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S)ecific attention to "e dra*n to a## va#ve& in ca&t iron.

S!))ort detai#& on a## 'aor )i)e*or,.etai#& of ,no*n defect& acce)ted on co''i&&ioning.

3.2.+ O,e"$ti!n$) -i*t!"

i ate of in&ta##ation of origina# &%&te'.

ii ate of in&ta##ation of ei&ting &%&te' *(ere it differ& fro' t(e a"ove.

iii O)erating (o!r& of #a&t in&)ection.

iv N!'"er& of (ot+ *ar' and co#d !nit &tart& at #a&t in&)ection+ *it( "e&t!dge'ent of feed train &tart&+ a& defined in 6))endi 6.

v %)ica# 'ai'!' te')erat!re gradient acro&& (eav% &ection& !nder

)a&t o)erating regi'e in ca&e 'ea&!re'ent& are avai#a"#e at &tation&.

vi 6 "rief &!''ar% of )ro"#e' area& and fai#!re& e)erienced to date.

3.2./ In*,ecti!n $n' M$inten$nce

i ate& of )a&t in&)ection&.

ii S!''ar% of finding& in eac( ca&e inc#!ding :

a Co')onent/area in&)ected

" Met(od of in&)ectionc Re&!#t&

d 6ction ta,en

iii Co')onent& re)#aced *it( date

iv ate of net )#anned in&)ectionv C!rrent e&ti'ate of re'nant #ife

vi Percentage ova#it% of )i)e*or, "end&

vii ate of )a&t c#eaning o)eration& inc#!ding :

a 6rea c#eaned*it( detai#& of i&o#ation re2!ired" Met(od& e')#o%ed *it( detai#& of c(e'ica#& !&ed+ if an%

c Re&!#t&

d etai#& of an% "efore-and-after )erfor'ance 'onitoring

viii ate of net )#anned c#eaning o)eration

i $or &!rface-t%)e (eater& on#% :

-ate of t!"e fai#!re& )#!& #ocation inc#!ding (eig(ta"ove/fro' t!"e)#ate face if 'ea&!red.

- etai#& of t!"e )#!gged )#!& 'et(od !&ed

-

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i o )rovide o)erating #i'it& t(at *i## 'ini'i&e co')onent

deterioration+ and

ii o )rovide e&&entia# )rotection for ot(er area& of )#ant fro'

fa!#t condition& ari&ing in t(e feed &%&te'.

+.2 Te in)ence ! !,e"$tin( c!n'iti!n* !n c!#,!nent )ie

6& a co')#e+ integrated &%&te'+ t(e feed &%&te' co')onent& can "e

&!"ected to t*o di&tinct t%)e& of #ife-#i'iting 'ec(ani&'&. (e&e can "e

c#a&&ed a&:

i irect 'ec(ani&'&+ i.e. t(o&e ca!&ed direct#% on a co')onent "% off-

de&ign ec!r&ion& o!t *it( t(e feed &%&te'.

ii Indirect or ,noc,-on 'ec(ani&'& *(ere a co')onent i& &!"ect todeterioration d!e to a fa!#t condition in anot(er )art of t(e feed

&%&te'.

(e&e t*o t%)e& of 'ec(ani&'& *i## "e dea#t *it( &e)arate#%.

+.2.1 Di"ectActin( Mec$ni*#*

(e 'aor direct-acting 'ec(ani&' affecting feed (eater #ife i& t(er'a#

fatig!e.

(e rate of c(ange of &!rface te')erat!re on t(e (eav% &ection&+ )artic!#ar#%of HP &!rface-t%)e (eater& can give ri&e to ece&&ive te')erat!re gradient&

acro&& t(e &ection. (i& co!)#ed *it( &tre&& concentrating feat!re& &!c( a&&'a## radia# c!rve& or coar&e 'ac(ining 'ar,& can #ead to (ig( &train+ #o*

c%c#e fatig!e crac,ing.

In etre'e ca&e&+ ra)id (eating or coo#ing tran&ient&+ co!)#ed *it( ei&ting

crac,& or defect&+ can #ead to fa&t "ritt#e fract!re.

+.2.2 In'i"ect Mec$ni*#*

So'e ea')#e& of t(e indirect 'ec(ani&'& invo#ved in #i'iting co')onent#ife in t(e feed &%&te' are:i !"e fo!#ing

ii !"e fai#!re

iii $ai#!re of interna# &(ro!d&

iv $ai#!re of ade2!ate drain& contro#

v Over)re&&!ri&ation

vi $ai#!re of &(e## oint&

vii $ai#!re of *ater"o divi&ion)artition )#ate integrit%/&ea#ing


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$o!#ing on eit(er &!rface *i## red!ce t(e (eat tran&fer coefficient HC of t(e

ne&t+ t(!& red!cing t(e feed o!t#et te')erat!re and t(e degree of drain&coo#ing if an%. (e effect of t(e for'er on &!"&e2!ent (eater& i& to increa&e

t(eir re2!ired "#ed &tea' f#o*+ *it( t(e )o&&i"i#it% of vi"ration da'age to

t!"ing and &tea' in#et geo'etr%.

(e effect of t(e #atter on drain& &%&te'& i& to #ead to f#a&(ing and

con&e2!entia# cavitation ero&ion in drain #ine&+ orifice&+ va#ve& and receiver&.

!"e fai#!re i& t(e co''one&t ca!&e of (eater #ife #i'itation+ in t(at a finite

e#e'ent of (eat tran&fer &!rface i& re'oved *it( eac( )#!gged t!"e. Ca!&e& of

fai#!re var% fro' ero&ion d!e to (ig( #oca# ve#ocitie& of conden&ate dro)#et& to

vi"ration-ind!ced *ear eit(er or fied "aff#e )#ate& or+ in etre'e ca&e&+ "%t!"e >c#a&(ing?: at anti-noda# )oint&.

(e con&e2!ence& of t!"e fai#!re are to #i'it t(e #ife of t(e (eater concernedand to a))#% a greater #oad to &!"&e2!ent (eater&.

(e fai#!re of interna# &(ro!d& &!c( a& t(o&e *(ic( de#ineate de&!)er(eatingor drain& coo#ing &ection& of HP Heater& !&!a##% re&!#t& fro' (ig( &train+ #o*

c%c#e fatig!e ind!ced "% "ad de&ign co!)#ed *it( differentia# e)an&ion rate&.

S(ro!d fai#!re can #ead to t!"e da'age "% t(e introd!ction of conden&atedro)#et& into de&!)er(eater 9one&+ and to co')#ete #o&& of drain& coo#ing d!e

to t(e introd!ction of &at!rated conden&ate and/or &tea' into t(e drainage

#eaving t(e &(e##. (i& in t!rn *i## (ave &erio!& ero&ion effect& on t(e *(o#e

of t(e drainage 'anage'ent &%&te'. 6de2!ate drainage #eve# contro# i&e&&entia# on a## feed &%&te'&. oo (ig( a #eve# *i## #ead to an ece&&ive

n!'"er of (eater tri)& *it( con&e2!entia# t(er'a# &(oc, tran&ient&@ too #o* a#eve# *i## #ead to t*o-)(a&e f#o* in t(e drainage &%&te'+ *it( con&e2!entia#

da'age a#read% detai#ed.

(e over)re&&!ri&ation can occ!r in deaerator& *(en t(e HP (eater drain& are

#ed direct#% to t(e deaerator via orifice )#ate&. $ai#!re+ or even 'aor *ear+ of

t(e&e orifice& co!#d #ead to t(e deaerator "eing over)re&&!ri&ed at a rate *it(

*(ic( t(e re#ief va#ve& are !na"#e to co)e. (i& i& )otentia##% dangero!&.

$ai#!re of t(e integrit% of t(e *ater"o divi&ion )#ate )artition )#ate+ or it&&ea#+ #ead& to invo#!ntar% "%)a&&ing of t(e t!"e ne&t and con&e2!ent #o&& offeed o!t#et te')erat!re.

+.3 E**enti$) P"!tecti!n !" Ote" P)$nt "!# F$)t* O"i(in$tin( in te Fee'

S*te#

(e greate&t ri&, to ot(er )#ant fro' feed &%&te' fa!#t& i& t(e )o&&i"i#it% of

*ater+ eit(er feed or conden&ed "#ed &tea'+ "eing ind!cted into t(e t!r"ineeit(er a 'ain t!r"ine or a oi#er $eed P!') !r"ine $P.


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(e &it!ation can ari&e fro' eit(er a "#oc,ed (eater drain& &%&te' or a

'!#ti)#e t!"e fai#!re in a &!rface t%)e (eater. (e ingre&& of *ater into t!r"ineand t(e on-#oad te&ting re2!ire'ent& detai#ed t(erein+ )artic!#ar#% *it( regard

to t(e d!)#icate f#oat &*itc(e&+ &(o!#d "e rigid#% ad(ered to+ for t(e on-#oad

te&ting of "#ed &tea' non-ret!rn va#ve&.

+.+ Re%i"e' M!nit!"in( In*t"#ent$ti!n

Man% of t(e #ife-#i'iting 'ec(ani&'& can on#% "e detected+ on-#oad+ "% t(eir&econdar% effect&+ &!c( a& a #o*er feed te')erat!re ri&e acro&& a given (eater+

or a #o&& of &!"-coo#ing in t(e drainage f#o*.

Provi&ion &(o!#d "e 'ade for t(e fo##o*ing )ara'eter& to "e 'onitored in

&ervice !&ing &!ita"#e )re&&!re ta))ing& and t(er'oco!)#e&+ on a## feed (eater&

i $eed *ater in#et te')erat!re

ii $eed *ater o!t#et te')erat!re

iii $eed *ater f#o* )er train if avai#a"#e ot(er*i&e tota# feed f#o*

iv #ed &tea' te')erat!re at (eater in#et

v Heater &(e## )re&&!re

vi rain& o!t#et te')erat!re

6## t(e a"ove &(o!#d "e avai#a"#e to t(e o)erator and recorded "% t(e Station

on a 'ont(#% "a&i& for f!t!re ana#%&i&/a!dit )!r)o&e&.

In addition+ t(e conden&ate #eve# in a## (eater& &(o!#d "e c#ear#% indicated#oca# to t(e (eater and+ de&ira"#%+ at t(e o)erator?& contro# de&,.

+./ Inte"i# A""$n(e#ent*

In t(e a"&ence of a!to'atic data #ogging e2!i)'ent+ t(e fo##o*ing 'an!a#

record& &(o!#d "e ,e)t for a## avai#a"#e 'onitoring )o&ition& 'ont(#%:

i $eed *ater in#et te')erat!re

ii $eed *ater o!t#et te')erat!re

iii $eed *ater f#o*

iv #ed &tea' te')erat!re

v Heater &(e## )re&&!revi rain& o!t#et te')erat!re

+. O,e"$tin( Li#it*

(e rate of ret!rning t(e feed &%&te'+ or an% )art of t(e feed &%&te' to &ervice

on t(e feed &ide &(o!#d "e governed "% t(e rate of te')erat!re c(ange acro&&t(e (eav% &ection&.


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O)erating in&tr!ction& &(o!#d "e dra*n !) for eac( &tation+ "a&ed on data on

(eater 'eta# te')erat!re& ver&!& feed in#et te')erat!re&+ gat(ered fro' t(ein&tr!'entation.

(e o)erating in&tr!ction& &(o!#d "e defined in ter'& of #engt( of )receding&%&te' o!tage and avai#a"#e feed *ater in#et te')erat!re.

(e rate of a))#ication of "#ed &tea' *i## "e dictated "% t(e ca)acit% of t(e

drain& contro# &%&te' to 'aintain contro# of (eater #eve#& *it(in t(e nor'a#o)erating range.

/. PLANT MAINTENANCE AND MODIFICATION

/.1 Objective*

o identif% t(e content and ti'ing of )#anned 'aintenance+ to o!t#ine a

)roced!re for for'!#ating c#eaning/in&)ecting/re)air/ref!r"i&('ent &c(e'e&@

to identif% t(e con&ideration& regarding t(e introd!ction of 'odification&.

/.2 P)$nne' M$inten$nce Activitie*

(e&e &(o!#d "e "a&ed on t(e re&!#t& of )revio!& in&)ection& and on )ro"#e'&

identified on &i'i#ar t%)e of (eater&.

8(en (eater& and t(eir a&&ociated )i)e*or, are o)ened !) on t(e *ater&ide+

)artic!#ar attention &(o!#d "e )aid to :

i Integrit% of feed in#et+ o!t#et and "%)a&& i&o#ating va#ve&.

ii (e condition of )i)e*or,+ and ade2!ate &!))ort &%&te'&.

iii N in&)ection of t(e area& of t(e *ater"o. Circ!'ferentia#

&,irt/*ater"o *e#d roof+ divi&ion )#ate &!))ort "rac,et *e#d&+ interna#

area& adacent to "ranc( )i)e&+ acce&& door rece&&+ *ater"o to )i)e*e#d&+ eterna# !nction of *ater"o and "ranc( )i)e& and t!"e)#ate

#iga'ent& and t!"e )#ate.

iv !"e interna# c#ean#ine&& / fo!#ing. (e need for c(e'ica# and/or

'ec(anica# c#eaning of t!"e& &(a## "e dictated "% :a (e degree and t%)e of fo!#ing di&covered and+

" 8(et(er or not a t!"e-*a## t(inning N in&)ection i&

re2!ired.

v 6n% )artic!#ar e'erging )attern of t!"e fai#!re&+ t(e degree and rate oft!"e fai#!re 'a% indicate t(e need for t!"e-*a## t(inning &!rve% !&ing

a))ro)riate tec(ni2!e.

On t(e deaerator& )artic!#ar attention &(o!#d "e )aid to t(e in&)ection of

&tr!ct!ra# *e#d& toget(er *it( &e#ected "ranc( and attac('ent *e#d&. (e


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re&!#t& of t(e&e in&)ection& &(o!#d "e recorded in t(e feed &%&te' &tat!&

record& 6))endi-1 to 5.

/.3 P"eventive M$inten$nce

8(ere a )artic!#ar area of a ne&t (a& "een identified a& "eing )rone to on-#oadt!"e fai#!re+ a t!"e*a## t(inning in&)ection &(o!#d "e carried o!t on t(i& and

ot(er &i'i#ar (eater&.

e)ending on t(e rate of t!"e fai#!re& and on t(e origina# t!"e *a## t(ic,ne&&+

a #eve# >a##o*a"#e *ear? *i## "e e&ta"#i&(ed+ *it( a## t!"e& detected *it(

greater *ear "eing &acrificia##% )#!gged.

/.+ M!'iic$ti!n*

8(en a ne* (eater i& re2!ired+ t(e fo##o*ing o)tion& &(a## "e con&idered :i Re-t!"e of t(e ei&ting t!"e)#ate / (eader to t(e origina# ne&t de&ign.

ii Re-t!"e of t(e ei&ting t!"e)#ate / (eader to a 'odified ne&t de&ign+

)artic!#ar#% a& to de&!)er(eating and drain& coo#ing arrange'ent&.

N!te 4 ot( of t(e a"ove o)tion& are de)endent on t(e t!"e)#ate / (eaderintegrit% "eing e&ta"#i&(ed "% co')re(en&ive N.

iii Re-t!"e of a ne* t!"e)#ate / (eader "!t !&ing t(e ei&ting &(e##.

iv Re-t!"e of a ne* t!"e)#ate / (eader "!t re-!&ing t(e *ater"o.

v Re)#ace'ent of a co')#ete (eater to t(e origina# de&ign.

vi Re)#ace'ent of a co')#ete (eater to a ne* de&ign to i')rove #ife /

integrit%.

(e fina# &e#ection &(o!#d "e "a&ed !)on econo'ic con&ideration&@ ti'e &ca#e

and #i'it& i')o&ed "% t(e ei&ting )i)e*or, and &!))orting &tee#*or, andfo!ndation &tr!ct!re&.

. LIFE ASSESSMENT

.1 Objective*

o define a 'et(odo#og% for deter'ining t(e degree of co')onentdegradation and identif% t(e action re2!ired to a&&!re contin!ed &afe+ efficient

o)eration to a )redicta"#e #i'iting #ife.

.2 C#)$tive Tbe F$i)"e

8(i#e not affecting )#ant &afet%+ t(e c!'!#ative effect of t!"e fai#!re& on

(eater efficienc% a& indicated "% ter'ina# te')erat!re difference i& t(e

co''one&t ca!&e of #ife #i'itation. Hence t(e !&tification for )#antre)#ace'ent in t(i& ca&e *i## "e 'ade on econo'ic gro!nd&.


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6n a&&e&&'ent &(o!#d "e 'ade+ for eac( &tage of feed (eating+ of a dat!'

#eve# of )ercentage &!rface #o&& a"ove *(ic( a )#ant re)#ace'ent &c(e'e'ig(t "eco'e via"#e. (i& a&&e&&'ent &(o!#d a#&o ta,e into acco!nt "ot(

c!rrent and )redicted rate& of t!"e fai#!re&+ and )ro"a"#e #ead-ti'e re2!ired to

o"tain re)#ace'ent )#ant.

(e re&!#t& of t(i& a&&e&&'ent for eac( (eater &(o!#d "e entered in t(e feed

&%&te' &tat!& record&.

Once an% (eater (a& reac(ed it& dat!' #eve#+ a &)ecific a&&e&&'ent of t(e

financia# ca&e for it& re)#ace'ent &(o!#d "e carried o!t. S(o!#d t(i& ca&e fai#

to 'eet c!rrent criteria+ t(e eerci&e &(o!#d "e re)eated at #ea&t ann!a##%+ !nti#&!c( ti'e a& a ca&e can "e 'ade.

.3 C"$c5 0"!6t $n' Te"#$) F$ti(e

%)ica# te')erat!re )rofi#e& for (ot+ *ar' and co#d &tart& fro' t(e )#ant&tat!& record& &(o!#d "e !&ed *it( c!rrent (ig( &train fatig!e end!rance data

to )redict t(e n!'"er of eac( t%)e of &tart c%c#e re2!ired for critica# crac,

de)t(. (i& &(o!#d "e done on one (eater )er &tation.

(e a&&e&&ed #ife &(o!#d t(en "e ca#c!#ated for eac( affected (eater !&ing t(e

"e&t data avai#a"#e on t(e act!a# n!'"er of c%c#e& e)erienced "% t(e )#ant.

C!rrent advice t(at crac,& &(o!#d not "e gro!nd o!t+ ot(er t(an &(ort &ection&for t(e )!r)o&e of crac, &i9ing if ot(er &i9ing 'et(od& are con&idered

inade2!ate. (e grinding &(o!#d "e contin!ed to a de)t( of 4'' "e#o* t(ecrac, ti)& to re'ove t(e 'o&t da'aged 'ateria# and ever% effort &(o!#d "e

'ade to )rovide &'oot(#% radi!&ed )rofi#e&.

6 dat!' #eve# N in&)ection and a&&e&&'ent of c!rrent crac, de)t( &(o!#d

"e carried o!t on eac( (eater *ater"o / (eader a& &oon a& i& )ractica"#e+ and

t(e re&!#t& noted in t(e feed &%&te' &tat!& record&. (ereafter &i'i#arin&)ection& and a&&e&&'ent& &(o!#d "e carried o!t a& nece&&ar%.

E)erience (a& &(o*n t(at t(e initiation of t(er'a# fatig!e crac,ing i& notnece&&ari#% indicative of i''inent co')onent fai#!re.

(e a&&e&&'ent of t(e f!t!re #ife of t(e (eav% &ection &(o!#d t(erefore "e

"a&ed !)on t(e a))rai&a# and 'onitoring of an% crac,& fo!nd in t(e o!tagein&)ection+ in co')ari&on *it( t(e )revio!% noted dat!' fig!re&. (e defect

a))rai&a# &(o!#d "e carried o!t "efore t(e !nit i& ret!rned to &ervice to

deter'ine t(e need for an% i''ediate action+ and t(e interva# "efore re-in&)ection.


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(e defect a))rai&a# a&&e&&'ent &(o!#d ta,e into acco!nt t(e )a&t and

antici)ated f!t!re o)erationa# )attern&+ 'an!fact!ring and re)air detai#&+ andin(erent de&ign integrit%. (e a&&e&&'ent &(o!#d "e "a&ed !)on )a&t

e)erience+ &tre&& ana#%&i&+ fractogra)(ic and 'eta##!rgica# &t!die& a&

a))ro)riate. (e re&!#t& &(o!#d "e inc#!ded in t(e feed &%&te' &tat!& record&.

.+ In*,ecti!n P"!ce'"e*

(e t!"e-*a## t(inning in&)ection and t(e crac, de)t( 'ea&!re'ent& &(o!#d"e carried o!t to defined )roced!re&. (e )roced!re& &(o!#d cover t(e N

tec(ni2!e& to "e !&ed+ t(e 'ea&!re'ent& re2!ired and t(e 'et(od of

recording.

(e re&!#t& of a## in&)ection& &(o!#d "e inc#!ded in t(e feed &%&te' &tat!&

record&.

7. RE8IE9

(e Head of Cor)orate O)eration Service& *i## "e re&)on&i"#e for revie*ingt(i& doc!'ent on a 3 %ear#% "a&i&+ or a& and *(en re2!ired.


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APPENDI:A

DEFINITION OF START CATE0ORIES

(e categorie& defined "e#o*+ re)re&ent "e&t c!rrent )ractice and &(a## "eado)ted for a## f!t!re )#ant. Ho*ever+ *(ere anot(er categori&ation i& a#read%

e&ta"#i&(ed a c(ange i& not re2!ired "!t t(e categori&ation e')#o%ed '!&t "e

defined in t(e feed &%&te' &tat!& record.i Co#d &tart+ after a &(!tdo*n )eriod eceeding B4 (r&. 'eta#

te')erat!re& "e#o* =0 of t(eir f!## #oad va#!e& in 0C.

ii 8ar' &tart+ after a &(!tdo*n )eriod of "et*een 10 (r&. and B4 (r&.

'eta# te')erat!re& "et*een =0 and 0 of t(eir f!## #oad va#!e& in0C.

iii Hot &tart+ after a &(!tdo*n )eriod of #e&& t(an 10('eta# te')erat!re&

a"ove 0 of t(eir f!## #oad va#!e& in 0C.iv 7er% (ot re&tart+ *it(in 1(r. after a !nit tri) or after feed (eater "an,

tri) 'eta# te')erat!re& at or near t(eir f!## #oad va#!e&.

Note:If these are not recorded in a particular station then records (i)to (iii) are sufficient.


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APPENDI:B1

FORMAT OF TURBINE FEED SYSTEM STATUS RECORDS

6 &ing#e !nified for'at for t(e feed &%&te' &tat!& record i& not a))ro)riate in

vie* of t(e *ide variation in circ!'&tance& t(at *i## ei&t.

(e fo##o*ing for'at i& )re&ented a& an ade2!ate ea')#e+ for an i'aginar%

ca&e *(ere t(e i')ortance of t(e )#ant invo#ved (a& !&tified a f!##

i')#e'entation of t(i& code of )ractice+ "!t *(ere no 'aor (a9ard i&

recogni&ed and *(ere t(e #ife #i'itation i& a#read% identified *it( ade2!ateengineering and "!dgetar% )rovi&ion in (and.

It *i## "e &een t(at t(e &!gge&ted for'at doe& not ca## for a## re#evantdoc!'entation to "e "ro!g(t toget(er. On#% doc!'ent& nece&&ar% for t(e

ongoing o)eration and engineering 'atter& are a))ended to t(e doc!'ent.

In ot(er circ!'&tance& &!c( a& *(ere one or 'ore (eater& are &een a& "eing at

ri&, and in need of inve&tigation it *i## "e nece&&ar% to "ring toget(er a## t(e

infor'ation for co')re(en&ive inve&tigation. (e ot(er etre'e *i## "e*(ere a )er'anent di&)en&ation regarding i')#e'entation (a& "een agreed.


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APPENDI:B2

FEED SYSTEM STATUS RECORD

SE6M SO

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APPENDI: B3

OPERATIONAL -ISTORY

i

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APPENDI:B+

INSPECTION AND MAINTENANCE

6E 6N

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APPENDI:B/

RUNNIN0 RECORDS

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oc!'ent for i&tri"!tion to :

CONTROLLED

I. Po,e" S!!o

1. General Manager Rihand2. General Manager Vindhyachal

3. General Manager Kahalgaon

4. General Manager Farakka

5. General Manager Dadri (oal ! Ga"#

$. General Manager %nchahar

&. General Manager Kor'a

. General Manager Ra)ag*nda)

+. General Manager ,adar-*r

1. General Manager /alcher Kaniha

11. General Manager 0nta

12. General Manager /alcher /her)al

13. General Manager Kaya)k*la)

14. General Manager i)hadri

15. 0ddl. General

Manager(#

ingra*li

1$. 0ddl. General

Manager(#

Kaa"

1&. 0ddl. General

Manager(#

,06 a-ti7e

1. 0ddl. GeneralManager(#

0*raiya

1+. 0ddl. General

Manager(#

8hanor Gandhar

2. Dy. General Manager(# Farida'ad

21. Dy. General Manager(# /anda

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UNCONTROLLED

II Reo He2 4"!e"

22. 9ec*ti7e Director (NR#; 0llaha'ad

23. 9ec*ti7e Director (R#; atna

2$. 9ec*ti7e Director (NR#; Ne Delhi

III Co"5o"!e He2 4"!e"

2&. hair)an ! Managing Director; 6>9; Ne Delhi

2. Director (/echnical#; 6>9; Ne Delhi

2+. Director (6-eration"# ; 6>9; Ne Delhi

#$. Director (o))ercial#; 6>9; Ne Delhi

31. Director (>ro?ect"# ; 6>9; Ne Delhi

32. 9ec*ti7e Director (6#; 96; Noida

33. 9ec*ti7e Director (9ngg.#; 96; Noida

34. General Manager (R!D#; Noida

35. oncerned Gro*-

Ogn Ops Mech 031

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