MASTER SHUT DOWN JOB LIST 2022- 410 TPH Boiler

Sr.No
Description Department Remark.
A WIND BOX & STRIPPER COOLER
1 TG side solid transfer line leakage attending work MMD
U/P
2 TG side PA duct to wind box belloe damage MMD Spare to be insure

Stipper Cooler PA air duct drain valve provision

Done
B HP BY PASS VALVE AND OIL SKID (KOSO)
3 KOSO HYDRAULIC PUMP -2 SRV Setting MMD/OPR/ISGEC PRESSURE ISSUE

4 HP -Bypass DSH Spray water control valve passing issues INST/MMD Spare to be insure

C STEAM LINE AND ISOLATION VALVE

4 MSSV gland heavy leakage MMD Spare to be insure
Gland replaced, fitting U/P
145 bar to 105 bar PRDS 29008 1st iso;ation valve gland leakage MMD HeavyLeakage

5 Main steam line to steam jet ejector spray water control valve 12 ty 29001 passing problem. INST It very difficult to maintain gland sealling temp

6 SJAE steam line PT modification work (Scaffoliding required) MMD /INS Next shut downto be carried out
Done
D SAFTEY VALVE
7 Main Steam safety valve setting work MMD

8 Drum safety valve setting MMD

9 SJAE safety v/v flange joint leakage attending work(with clamp) MMD Not to be attended

10 EMRV trial to be performed at time of stoppage (in presence of IJT) MMD

11 145 bar to 105 bar PRDS safety valve setting MMD

E DEAERATOR
12 Dearator vaccum breaker lekages MMD Frequently leakage after attending so many times work Done

13 Deaerator both loop spray water line SOV provision work due to individual isolation v/v INST New SOV required ( Spare to be insure)

F ESP AND FLY/ SILO

14 Silo Dump valve checking as per atteched sheet. MMD passing issue

15 Extra service air isolation valve provision work in ESP 1 & 2 flya ash system (Scaffoliding required) MMD 2 nos of valve required for effective isolation of FAS

16 Extra service air isolation valve provision work at silo (Scaffoliding required) MMD Spare to be insure

17 APH fly ash hopper 3,4,5,6 bypass line sliding gate valve proviosion work (Scaffoliding required) MMD Spare to be insure

G INSULATION / CLADDING
18 Skin Temprature very high around boiler drum area /pent house >200 Deg C MMD only top roof insualation is pending & it will be carried out next shut down
Not to be attended
H COMMON DRAIN AND VENT
19 Boiler FSH ATTEMPTERATOR. 2 sov 28002 gland leakage attending work INST
Done
20 CBD line before MOV 26001 isolation valve gland leakage MMD

21 Comman drain header drain valve no-3 & 16 isolation valve gland heavy leakage MMD
Done
22 TG side drum to local level glass line 1St isolation valve gland leakge (top Side) MMD

23 Drum local pressure gauge 2nd isolation valve gland leakage MMD

24 Reheater Strat-up vent control valve gland leakage Inst Spare to be insure

25 Drum LT 26001C & B high side plug leakage (air vent port) Inst

26 COD drain line 1st root isolation valve handle not available so need to replaced MMD

27 BHEL MS line drain 1st isolation valve gland leakage MMD near BFP

28 105 bar PRDS in-let after Control valve 29008 drain pass MMD Deaerator

29 TG side drum vent valve passing 2 " MMD Drum floor

30 CT side saturated steam line vent passing :1" MMD Drum floor

31 Reheater in let (CRH) line drain pass & Steam trap passing 1" MMD

32 COD vent valve passing at Cooling tower side MMD Valve not availability

33 Hanger tube line PT first isolation valve TG side replaced (previously on line done so valve to be replaced) MMD/INST Valve not availability

34 Extrta isolation valve provision work TG side DRUM vent line : no. 6 (passing 100 degree) 12DD26024 MMD Valve not availability

35 Extrta isolation valve provision work TG side PSH vent : no. 1(passing 100 degree)12EE27061 MMD Valve not availability

36 Extrta isolation valve provision work CT side compact seperator vent line : no. 3 12DD26078 MMD Valve not availability

37 WW 2 all 06 common drain line isolation valve provision work 12EE28002 MMD Valve not availability

38 Extra isolation valve provision work in hanger tube outlet line to DRUM vent line TG side MMD Valve not availability

39 REHEATER sample line de chocking work MMD

40 4 NOS of SWAS in-let valve passing(1.Saturated steam 2.reheter.3 CBD.4 super heater) INST/MMD Valve not availability

I SOOT BLOWER
41 Soot blower before control valve isolation vlve gland frequently leakage MMD

42 Soot blower steam line MOV-28001 valve replacement work MMD Due to valve passing & heavey gland leakage

J FANS & BELLOW

43 All Fans IGV jamming issue MMD/OPR Every time jamming issue

44 SA fan -2 high vibration issue at VFD 72 % (more than value 6 mm/sec) MMD 1:40 AM SA FAN-2 NDE X AXIS VIB. CONTINUESLY HIGH UPTO 6.6MM/S AT 70%
VFD, 1055RPM.

45 PA fan -1 high vibration issue at VFD 82 to 84 % (more than tripping value 11 mm/sec) MMD Ø  1:40 AM PA FAN 1 NDE X AXIS VIB. HIGH 8.6MM/SEC AT 73.5% VFD, 1097
RPM.
K BFP
46 BFP I motor DE/NDE side oil flow checking work(leakage attending work) MMD

SWAS
Main steam sample line bend replacement work (near SAWS pannel ) MMD #3000 &1.5' SS bend

K OTHER JOBS
43 Boiler Roof sheetting work 20 % pending CIVIL Scaffoliding Work completed

PENDING ISSUE FROM M/s ISGEC

1 All CGF discharge pluggage not working. ISGEC

BFP lube oil pump Oil filter DPT around 2400 mmWC with single pump running but
in case of normal Pump Change over DPT rise  >6350 mmWC ( Tripping valve >6000
mmWC with 3 sec Delay) due to this Phenomena Both lube oil pump tripped and also
BFP trip During pump change over. This types of phenomena May lead to Plant black
2 BFP-Lube oil DP interlock issue ISGEC out in ( case of DPT malfunction) normal running of plant.Also note that already BFP
tripping interlock provided in lube oil Discharge pressure < 0.6 kg/cm, however BFP
tripping interlock provided in lube oil filter DPT so please clarify why tripping given
on filter DPT. Also suggest at which valve (DPT) lube oil filter required to change over
the filter.

3 O2 Analyser installed in only one side-During charging over of DCF /Maintain O2 is fluctuating. ISGEC It is as per approved drawing and momentary changes are quite norma during DCF
feeding rate change..However additional O2 analyser can be added.

O2 Not maintain during coal DCS -1 & 6 normal shut down condition ISGEC It is recommended to run both DCF in operation. Site team to plan maintenance
accordingly
4
 April 2022 shutdown
SR NO. JOB DESCRIPTION SCOPE AREA REMARKS
1 Drum LT 26001C & B high side plug leakage (air vent port) INT. Lime bunker floor
2 Boiler MSSV gland leakage attending work MMD(MK) MMSV floor U/P
3 TG side solid transfer line leakage attending work MMD(MK) Boiler 1 st floor Done
4 BFP I motor DE/NDE side oil flow checking work(leakage attending work) MMD(MK)/ELE 100 m (TG) With load trial
5 Boiler common drain line no 3 and 16 gland leakage attending work MMD(MK) Steam common drain header
6 Boiler fsh att. 2 sov 28002 gland leakage attending work INT. Feed water station
7 35 bar PRDS positioner checking work INT. 116 m (TG)
8 Soot blower first isolation v/v gland leakaage attending work MMD(MK) Boiler Top Every time 2nd pump strated
9 12 MW Control oil pressure switch psl 8141/psll 8141 A/B/C checking work INT. 105 m (TG)
10 D/A vaccum breaker leakage attending work MMD(MK) 116 m (TG)
11 SJAE safety v/v flange joint leakage attending work(with clamp) MMD(MK) 100 m (TG)
12 12 MW 35 bar exhaust line drain pot local drain bend leakage attending work MMD(AB) 116 m (TG)
13 RE heater sample line de chocking work OP./MMD 116 m (TG)
14 12 MW inlet MOV checking work INT./ELE 111 m (TG)
15 Koso oil pump no 2 PRV checking work MMD(AB) 103 m (TG)
16 MSL BHEL drain line 1 st isolation v/v gland leakage att. Work MMD(MK) 100 m (TG)
17 EMRV trial to be performed at time of stoppage (in presence of IJT) MMD(MK) MMSV floor
18 SA fan -2 high vibration issue at VFD 72 % (more than value 6 mm/sec) MMD(MK) Boiler ground floor
19 PA fan -1 high vibration issue at VFD 82 to 84 % (more than tripping value 11 mm/sec) MMD(MK) Boiler ground floor
 April 2022 shutdown
SR NO. JOB DESCRIPTION SCOPE AREA REMARKS
BOILER - E
1   Combustor Front Side Seal box leakages near to SA Nozzle.

2 SA Nozzles Flanges leakage to be arrested- Leak test Is required in other flanges also.
3 Co Vent provision.
4 Down comer Spring support cleaning / and replacement.
5 APH seismic Support cleaning . No Job done till now.
6 PA duct support welding – vertical support near to wind box.
7 SH drain header valve passing.
8 Eroded insulation sheets to be replaced .
9 Coal chute leakages.
BOILER - D
1   Return Leg flue gas leakage at furnace seal box.
2 Bed material floor cleaning.
3 Air leakage to be checked at Bed material feeder outlet flange.
4 Economizer drain line online leakages.
5 Spring support damages at feed line.
6 Expansion indicator permanent fixing .
7 PH casing leakages at LHS.
8 APH inlet duct insulation. No Job done till now.
9 APH duct vibration-  additional support is required .
10 APH duct cleaning.
11 ESP inlet flange air  suction .
12 Return leg duct inspection for analysis back pressure at DCF.
13 FF RAV gland leakages.
14 ID fan outlet damper cover plate damaged need to be remove( eroded)
15 Bed material outlet valve – need to change IGV to avoid air loss.