Lt : s

EVENT ANALYSIS REPORT

NITNO: 5 TPS: Khaperkheda TPS Unit Capacity: 500 MW
Date:- No. of days from last sync. i- L7
1. *HO Code: Station Code:-TE05/1 5- 15 Time:- 07:51 Hrs.
23.08.2015 Days
2. Operating conditions at the time of Event
Coal Cvcles in service Oil Suooort
B,C, D, E, F,G

3. Nature of Event: Set Withdrawn due to Boiler Tube Leakage.

4. Name of First Up, Main Protections & protection on which GCB tripped:
Boiler Tripped On:- Boiler Tripped on Flame Failure.
Turbine Trippd On:- Boiler tripped.
5. A) Obervatiom - Suspected Boiler Tube Leakage near Water Wall Soot Blowers No. 69 and 47 . Also on Dtd :23108/2O15, DM
lWater Consumption was increased.
lfm It : 2nd Tube at LHS of WWSB No. 69 found punctured due to wear and at upstream near WWSB No 47, failure type is thick lip
iopening (2nd tube at RHS) along with secondary damages to adjacent Tube at both LHS and RHS Tubes.
5. Bf Remedial Action/work done :- Total No of HP Joints welded = 52 which includes primary as well as secondary Joints.

6. Root Cause Analysis :- 2nd Tube at LHS of WWSB No. 69 punctured due to wear and at upstream near WWSB No 47, failure type is
thick lip opening (2nd tube at RHS) may be failed because of starvation and overheating.
BM-ll) {Primary Failure} 1> At 20 Mtr. at Water Wall front panel (Looking from inside of Furnace and considering WWSB 69 as
center) 2nd tube at LHS of WWSB No.69.
2> Al 42 Mtr. at Water Wall front panel (Looking from inside of Furnace and considering WWSB 47 as center) 2nd tube at RHS of
WWSB No.47.
(Secondary Failure) 1> At 20 Mtr. WWSB-59 Looking from inside of Furnace and considering WWSB 69 as center. On RHS - 1 to 14
No. tubes including bend. On LHS - 1,3 to 8 no. tubes including bend.
2> At 42 Mtr. WWSB - 47 Looking from inside of Furnace and considering WWSB 47 as cente. On RHS - 1 No. Tube i.e. tube No . 3rd
and on LHS - 2 No tubes i.e. tube No. 2nd and 3rd.

7. Preventive action suggested (Short Term) :- All Punctured and Worn Out tube replaced. Tube Thickness survey analysis will be
carried out during AOH. Sample will be sent for metallurgical analysis to detect the exact root cause of failure.
8. Prerentive action suggested (Long Term) :- NIL

9. Similar event occurred last time:

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

10. Boiler lighted up :

Time - 2O:50 Hrs.
11. T-A Set Synchronised Time - 04:28 Hrs. Date- 26.O8.2015
12. Remarks :

13. Reconimendations 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 remedial action is completed satisfactory & point is closed :

CE/DycE(Works)
*HO Code will be given by Works Section.
 Doc. No.
Rev. No'
KHAPERKHEDA T.P'S' Rev. date :

EVENT ANALYSIS REPORT

TRIPPING , NON'TRIPPING
EVENT NO. :

UNIT NO :

DATI 12
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1> EVENI bu suPPoRT
2> OPE

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TRIPPING
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MALISATION

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SHIFT\T'TCHARGE
NAME :

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2>WORKS CARRIED
OUT:- N o +teetQtc cr:oxrcs C-c\lrlc.'r-ou-ts&^^!+trBlL'

RESPONSIBILITY
TARGET DATE
BOVE :

CORRECTIVE ACTION
TO AVOI'
].

E.E.( l&c-l
'{;
E.E.( TESTING-llN NAME :- 1l. A " De--
NAME:-\ . ft. Deso-l
 C} TO BE RECORDED BY MAINTENANCE SECTION :

1> ANALYSIS OF TRIPPING & PROBLEM FACED DURING

LIGHT UP & SYNCH*O*''O,,* .-

2> WORKS CARRIED OUT :-

CORRECTIVE ACTION TO AVOID REOCCURRENCE OF ABOVE

:
RESPONSIBILITY TARGET DATE

PM gd^eAt'le- +ttf 6fL neoa. WtilgB-f q e+Z

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E.E.( EM-ll ) E.E.( TM-ll)
NAME : NAME :
D> REMARKS :

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s.E. ( oP-il )
s.E. ( M-il )

DY"NK=R-'
Note : Please attach separate sheet, where required.
Note : Please attach DAS alarm & Trend curve print out
 REPORT OF BOITER TUBA FAILURE AT UNIT NO. 5 [500 MW)
KHAPNRKHEDA T,P.$"
DATE i 26.08.2015

1st Psss Water Wall Tubes Zone

Location J-st Pass Frnnt Water Wall Panel Tubes at nlevation 20 Mtr. &.47

Primary Failure 1_. At 70 Mtr" at W.W, front panel { Looking fi'om inside of furnace ancl
cr:nsicler"ing WWSB 69 as centre J Tnd Tube at [,HS af WWSB No. 69
h4tr. at !V"W. front panel ( Looking frr:m insidE nf ftlrnace ancl
rr
A. At 42
considering WWS I3 47 as centre J fnd Tube at RI{S WWSB No,47

Secon d,ary Fa:ilu.re
L. At 20 Mtr. W14/SB - 69 - Looking frotn inside of f'urnace and considering
WWSB 59 as centre. 0n RI"IS - L to 1"4 no tubes including bend' 0n LHS
*
l-,3 to B no tubes including bend.
2. At 4?, Mtr. WWSB ' 47 " Looking from inside of the furnace and
considering WWSB 4'7 as centre. 0n RHS - 1 no tuhes i.e, tube no 3'd &
0n LI{S - 2 no tubes i.e, tube no l*d 6pfl lrd.

Tube Sl+ne 51 X 5.6 * SA?ltl t}: C fWaler lAlallJ

No. of ,H.P, weld foints @ 52 |oint [Prirnary & SecondarYJ
Unit wi,thdrawn at On Iltcl .'n.08 "2A1 5 at 7:51 Hrs.

Unit cleat"ailce glven On dtd ^').5.08.20"15 at 3 4:35 Hrs.

for Hydraulic Test at
Unit clearance given 0n dtd. 25.08.2015 at ?0:L0 Hr"s.
for Boiler tight up af
Outage hours i 60:19

No. of days since last 72 Mr;nlh,

Overhaul.
Roat Cause of failure Znd Tube at LHS of WWSB No. 69 punctured due to wear and at
upstream near W.W.S"B. No. 47 failure type is thick lip opening [Znd
Tube at RI{S) may be failed because of starvation & overheating.

SB-servation Znd T'ube ar LHS of WWSB No. 69 found punctured due to wear and at
a
upstream near W.W.S,B. No. 47 failure type is thick lip opening (2"4
Tul* ,t IIHSJ along with secondary damages to adjacent tube at both
tHS & [tHS tubes. i

correc,t;ive & All puncture & wol"n out tttbe replaced. Tube J"hickness survey
,Frevenfive A*ti,an analysis will [:e carried out cturing A$H. Sanrple will t:e sent for
,metfllltirgical analy5is tO detect Cxnct t"t)Ol Cause nf failUre,

Executive f,ngineer {HM-II}

 5efrvn ,,- 6;lq raa,l"$'S,saz)fivJ K(KP'

WORK DONE DURING SHUTDOWN ON DTD. 23.O8.2OT5 TO 25.08.2015.

1) BTL at Front Water Wall near SB - 69 & 47,attended.

2) At C/F - A to D, F/F line laying & connecting to header work done.
3) All oil guns cleaning done.
+) Steam leakages of steam tracing line at GH-1. elevation attended.
5) At Feeder Floor elev. Corner No. 4 tracing line steam header replaced.
6) Coal Feeder - G, COC gear box replaced.
7) Coal Feeder - A to H, feeder outlet chute patch welding done.
8) Coal Mill & Coal Feeder- D, F, G & H+.M. done.
9) Coal Mill - A, C & D+4DV area coal dust leakage attended by patch welding.
10) WWSB - 69-sleeve fitting done & jamming removed.

11) Coal Feeder - A to H, coal removed near chute area.

12) Coal Mill - A to H &PA / FD / ID fans oil level checking done.
13) PA Fan - A, LOP - Bstrainer cleaning done.

' -. Exectrtive Engneer

Addl'
If, 500 Mw
BUI -
TPS
KhaPerkheda

fu,r
, . ^ _ ^Sg.Fryintending Enginear
[\4SPGCL, S00 MI4l TpS, Khape,*huif*
 MAHARASHTRA STATE POWER GENERATION CO. LTD.
/* KHAPERKHEDA THERMAL POWER STATION
ffiENCO
tlatrradb$hffiCo.LE
(lSO 9001:2@8, ISO L4AOL:2004 & ISO 18001:2@7)
Ofioe d Chief Engineer, T.P.S., Khapertheda, Dist. N4pur, PIN - 441102
Phone: (07 1 13) 258168 to t7 2,268235, 26813 1 FAX: 268239(0 W 268123 (Site)
ncah,ltOIlGttCl5l6aS E m a iI - cEFe nk.pJ<d.@m aF gFe.[9,p,!.n

Date: 2810812015
TURBINE MAINTENAI\CE-STAGE-II
UNIT NO. q S.Hpr DOWN REPqRT

500MW Unit No. 5, TG set was withdrawn on dated 23/08 /20L5,at 07:50 hrs. due to boiler tube
tcehage. Set was synchronised on dated 26/08/20L5 at 04:28 hrs. after carrying out fOllowing works at
turbine side auxiliaries.

sR. NO. WORKS CARRIED OUT

1 MOT lube oil duplex filters cleaned & box up done.

2 Moisture drained from instrument air drier filters in compressor room

3 Main turbine IOP filter changed over & S/B filter cleaning done.

4 TDBFP-B :- Following works carried out on TDBFP-B

4-a) Gland steam supply line welding done on leakage point.

4- b) MCV & I/H convertor spool cleaned & governing filters cleaning done

5 TDBFP-A :- Following works carried out on TDBFP-A

5-a) Booster pump vent valve gasket replaced with new one, ,

5-b) Booster pump discharge line drain line -btOing done on leakage point.

5-c) Booster pump discharge flange plug replaced with new one.

v
(
s-d) Booster pump parting plane belazona putty applied to stop parting plane leakage.

5-e) MCV & I/H convertor spool cleaned & governing filters cleaning done

6 HPWeldingWork:-

' 6-a) Dearator pegging line drain valve additional valve provided as it was passing.

6-b) Dearator level one nos. 1" (800 class) drain valve.

GSC drip line to flash tank line choke up removed & strainer cleaned. It steam trap found in
7 reverse direction hence it was cut & re-welded in proper direction. All the three manual
isolating valves seat checked and found ok.

LPBP control and stop valve leakage oil cleaned. LPBP - 2 stop valve hydraulic oil inlet pipe
B
(220Bar) found slight leaking at connector.

Comp-1 lD:FlOperating Data-30-04-20t3/Shut Down Report /SDR-28-08-2015/Page--1

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 MAHARASHTRA STATE POWER GENERATION CO. LTD. ..
:r

KHAPERKHEDA THERMAL POWER STATION &,

(lSO 9001:2008, tSO 14001:2004 & tSO 18001:2007)
U
{I(AS
0ffice of: chief,Engineer, T,P.s., Khapedrtreda, Db[ Nagpur, PtN - ulloz ttL.il(:4rlrhr
. !t ]r*,r .

P ho ne : (07 1 13 ) 2681 68 to t7 2,268236,268rg r rnX: 268239(

Atfl| 26g1 23(Site)
hQ.ltnI{ zws plc 1s3648 Email - cq&enf$kd"ern.qhgqencg.in
UES b r rnrrrbf el Rq,ddt',, at glyatrar0r, iHf {,i,.li!i LW.

I Decoupling of etc. hydrant pump 1 & 2, electric spray. pqnlp:done for motor drying purpose.

10
T:::''*1"1*t::':::15
Submersible dewatering pump (3 Nos.) with piping connection provided in RWp for
10-a)
dewatering purpose.

Electric spray pump discharge header pressure gauge line leakage attended & spare
10-b) Or*
gauge line dummied.

10-c) werding
::-:::3:1 11*::1i::: :':- ::1i:: "*"d"0 lryarch
10-d) Electric hydrant pump-1 coupling and alignment work done Trial found ok.

t0-eJ
Electric hydrant pump-2 dismantled for overhauling as its motor got burnt due to *.r.,
flooding.

L1. Diesel hydrant pump put in service due to emergency.

Spray pump discharge header charging done by opening inter connectlng valve of frydrant
L2
pump discharge he$r as spray pump motors got submerged in water.

t '( #**
&*\i
Dy. Ex. Enginer (TM-II)
500MW TPS, Khaperkheda
ir'
t

m,{w
Executive Engineer (TM-II)
500MW TPS, Khaperkheda

superinteni"f,'fttfi'-
500MW TPS, Khaperkheda
l

comp-1 lD:rloperating Data-30-04-2013/Shut Down Report /sDR-2s-09-201S/page--2