Ramagundam

BOILER MAINTENANCE PRESSURE PARTS

STAGE III OVERHAULS 2010
Sl.
No.
01
02

DESCRIPTION
Duration of Overhaul
Boiler Cleaning

03

Approach

04

Thickness survey

UNIT -VII
01/08/2010 to 24/08/2010
1. Internal cleaning with low pressure water Done in Pass-1&2
2. Cleaning with HP jet -Done
3. Scrapping Done over Water Wall Panel
1. Sky climbers 2 nos. erected
2. Quick erect scaffolding up to roof- Done
3. Platform below Z panel Done
4. Platen Reheater coils-4 Tier platform erected at front & rear coils
5. SHDP coils -5 Tier platform erected
6. Platen Super heater coils-4 Tier platform erected
7. SH / RH/ Rear RH coils spacer tube approach platform erected.
8. Platform for inspection of Eco inlet bends hangers at Eco hopper.
9. 3-tier Platform for LTSH Terminal Tube Inspection Erected.
10. For Steam Cooled wall front header stub DP platform erected.
Area
No. of Spots Taken
Z-Panel
4385
Wall Blower
6732
RH Bends
303
Gooseneck
981
Burners
287
SHDP
1303
Economiser
16560
LTSH
12524
Screen Tube
1216
Terminal Tubes
1488
Lifted Coils
2423
Total
48202
1

REMARKS

Ramagundam
05

HP Tube Replacement

Location

Joints welded

Radiography

PASS 1
Wall Blower
Corner Panel

525
47

525
47

Z-Panel
Reheater
TOTAL

42
15
629

42
15
629

Economiser
LTSH
Eco Inlet old Joints
Bifurcation

144
111
195
2

144
111
195
2

TOTAL

452

452

PASS 2

06

LTSH and Eco coils

07

Planned jobs as per

Action plan.

08

Non destructive testing

Lifted / Lowered

Adjacent coil Top Bank

inspected
LTSH
1 / 2 & 123/124
3/4,121/122
ECO
1/2 & 183/184
3/4 & 181/182
1. Old joints radiography 583 nos in eco inlet connection tubes.
2. Platen SH I/L header all stubs DP Done in all 25 Coils.
3. Steam Cooled Wall Front header stub joints DP carried out.
4. In all 124 LTSH coils T1,T2&T3 was locked with Clamps at
Hanger No. 1.
5. All the orifices are removed in bottom ring header and after
hydraulic test and flushing of the headers orifices were put back in
place.
6. CRH power cycle piping Hangers replacement done as per plan.
(a) RH start up vent stub, drain stub DP.
(b) DP on fin welding.
2

92 joints found defected.

OK
OK
To restrict Misalignment.

8 nos. Support Hangers were replaced.

All NDT tests completed

Ramagundam
(c)
(d)
(e)
(f)
(g)

09

Penthouse and dead

chamber inspection and
rectification.

10

Hanger inspection

11

Burners

12

Ducts

13

Safety Valves

DP on cleats welding.
DP on wind box attachments.
DP of steam cooled wall front header stub joint.
DP of platen SH inlet header stub joints.
Oxide Layer Thickness measurement carried out in Final RH,Platen SH
&Divisional Panel inside furnace as well as in Penthouse as per plan.
(h) 30nos. DMWin FRH & 40 nos. of FRH&PSH bottom bends
Radiography done.
(a) Penthouse
(a) Penthouse was found clean during
(b) Windbox
initial inspection.
(c) Dead chamber top
(b) In 55 mtr dead chamber no significant
(d) Dead chamber bottom.
ash accumulation observed..
(c) 10 mtr. Dead chamber seal boxes cut
and replaced with new ones at all the
four corners refractory filling for
sealing.
1. Penthouse support inspected and loose hangers were loaded.
Power cycle piping hangers inspected.
Hot & Cold Readings were taken.
(a) Coal compartments replaced.:- All were replaced with reconditioned
coal compartments.
(b) Coal compartments insitu reconditioned: - No insitu replacement.
(c) Other components replaced:-Nil
(d) SADC checking:- All SADCs were de linked and checked for freeness.
They were linked and checked for full opening and full closing
pneumatically.
(e) Burner readings at 0,+30,-30. Carried out.
(f) Oil burner alignment. Carried out.
(a) Cleaning.
Enclosed: Annexure I
(b) Details of works carried out
(c) Bracing replacement, shielding of bracing and patch welding.
(d) NMEJ replacement done in Hot primary air Duct.
Drum Safety valve SV3,SV4&SV6 Servicing Done.
MS Safety Valve SV8 Servicing Done.
3

Ramagundam

14
15
16
17
18

All Drum & MS Safety Valve Trivi Setting Done.

All Serviced Safety valve actual floating done.
ERV
SV-9,10,12,13,22.All pilot v/v serviced
RH attemperation valves SD 47,51&45 Servicing Done

19

SB line control valve

Any other major valve
Other conventional
valves
Valves replaced

SB 55&56 Servicing Done

CBD 72,73 & CRH NRV. Servicing Done
ERV B65&66 Servicing Done

20

SH attemperation valve SD-35,36,39&43 Servicing Done

21

Soot Blower

Feed water sample line v/v replaced.

Lance Tube Replaced in LRSB No. 107,108,109&110

Wall Blower at C&D elevation servicing done.

Details attached: Annexure -II

Ramagundam

ANNEXURE I
DUCT WORK DETAILS:
DESCRIPTION OF WORK
UM
Replacement of ducts bracing
Nos.
Removal & Rewelding of Protection plate .on duct expansion joints P/Mtr.
Patching of duct deflector plates
Sq.Mtr
Replacement of eroded gusset plates
Nos.
Removal & Rewelding of shields on duct bracings
Nos.
Replacement of NMEJ
Nos.

QTY
318
241
225
159
79
04

ANNEXURE-II
SAFETY VALVES ACTUAL FLOATING DETAILS:
Sl
No.
01
02
03
04

Safety Valve

Drum Safety Valve SV 3

Drum Safety Valve SV 4
Drum Safety Valve SV 6
MS Safety Valve SV 8

Design Lift
Pressure
kg/cm2

Lifting
Pressure
kg/cm2

Resetting
Pressure
kg/cm2

Blow Down in
%

211.1
211.1
213.2
188.5

214
211
214
188

192
199
204
182

6.13
5.69
4.67
3.19

Ramagundam
ANNEXURE-III
MATERIAL CONSUMPTION DETAILS:

Pass1OHWorks:

Material
Code

MaterialDescription

Unit

M0521990532
M1661210209
M1661210227
M2450321524
M2450321524
M2450321551
M2450341753
M4706020557
M4706020575
M4706040768
M4706130012
M4716020246
M4716020255
M4772100089
M4772100353
M4772100353
M4772290078
M4772450076
M4741010090
M4741010133
M0540153057

SPRLWONDMETLCGASKETSS316GRAPHITEFI
HOSEWATER:IS:444:1.0MPa:20MM
HOSEWATER:STD&GRIS:444:21MPaPR:25MM
TIGFILLERROD:MODEL/:2.40TGSM
TIGFILLERROD:MODEL/:2.40TGSM
WELDINGACCESSORIESTIGSIZE2.4MM
WELDINGACCESTIGFILLERWIRE2.4MM
WALLBLWRBEND51X56MMSA210RIFLED
WWBEND51X5.6MMSA210RIFLED.
FINBAR6X12.7BMC20FORWWTUBES
WWRINGHDRMANHOLESBOMO2SMA1H430
U7RHBENDTUBED63.5X4MMR200,60DEG
U7RHBENDTUBED63.5X4MMR200,120DEG
WATERWALLSMOOTHTUBE51X5.6SA210GRC
RIFLETUBE51X5.6MMSA210GR.C
RIFLETUBE51X5.6MMSA210GR.C
ST.TUBE54.0X4.0MMSA213T22
ST.TUBE63.5X4.0MMSA213TP347H
CARNSEALRNGSBOMO2SMA3U1780OILGUN
PINFOROILBURNRTILTSBOMO2SMA3U4180
PKGG:IS:4687/1DRYAS:SQ:3MM

NO
M
M
KG
KG
KG
KG
NO
NO
KG
SET
NO
NO
M
M
M
M
M
SET
NO
NO
6

Qty

Amount
10
120
76
10
15
10
5
18
20
400
1
1
1
250
100
200
0
20
5
10
35

4602.00
8040.00
5335.96
5805.20
8707.80
7543.60
4123.35
65757.96
95818.40
44160.00
799.21
6666.40
6666.40
241467.50
302648.00
605296.00
0.00
121841.40
2628.20
464.97
13297.90

Ramagundam
M0590113001
M4741010160
M4745010010
M4745020107
M4745020116

ASBESTOSCLOTHSTRIP3MM(T)X65MM
FLEXSEALTUBEASSYSBOMO2SMA3U0240
GKTFORCOUPLG24FORCOALBURNER
SQHDPIVOTPINSMA3U0730FORCOALBUN
REACDENDSBOMO2SMA3U1320FORCOALBUNR

KG
NO
NO
NO
NO
Total

51
8
24
10
10

10546.09
9886.00
9792.00
1731.08
439.01
1584064.43

Pass2OHWorks:
MaterialCode

MaterialDescription

Unit

M0171110249
M0141200259
M0141200259
M0521990532
M1661210209
M2415022552
M2415032029
M2415032029
M2415082024
M2450321524
M2450321524
M2450321551
M4704020047
M4711070060
M4711080111
M4711080111
M4711990105
M4772100131
M4772100168
M4772100210

RODSSCIRAISI:3046MM
SHEETSSAISI:3042.5MM
SHEETSSAISI:3042.5MM
SPRLWONDMETLCGASKETSS316GRAPHITEFI
HOSEWATER:IS:444:1.0MPa:20MM
ELECTRODESSRESISTING308163/3.15MM
WELDINGELECTRODEE309L16;2.5X350MM
WELDINGELECTRODEE309L16;2.5X350MM
WELDINGELECTRODEE8018B22.5MM*350MM
TIGFILLERROD:MODEL/:2.40TGSM
TIGFILLERROD:MODEL/:2.40TGSM
WELDINGACCESSORIESTIGSIZE2.4MM
FIXGBLTFORDRUMMANHOLEDOOR
SHSCFRONT6X100MMBMC20FORSH
ALIGNTCLAMPLTSHCOILS500MW.BLRSTII
ALIGNTCLAMPLTSHCOILS500MW.BLRSTII
STRAIGHTTUBE51.0X10.0MMSA210GRC
TUBE44.5X7.1MMGRADE:SA230T11.
ST.TUBE47.63X6.6MMSA213T11
ECONOMISERSTTUBESA210GRA1FORU7

KG
MT
MT
NO
M
NO
NO
NO
NO
KG
KG
KG
SET
KG
NO
NO
M
M
M
M
Total
7

Qty
50
1.344
0.96
3
122
483
960
768
625
10
10
5
2
200
100
100
20
20
50
150

Amount
10390.50
308827.87
220591.33
1380.60
8174.00
4801.02
24278.40
19422.72
3193.75
5805.20
5805.20
3771.80
1442.00
16920.00
85197.00
85197.00
17689.60
15424.40
222862.00
83935.50
1145109.893

Ramagundam

ValvesOHWorks:

MaterialCode

MaterialDescription

Unit

M0520990301
M0521990347
M0540161263
M0540361142
M0540361328
M0540361328
M0540361373
M0540361683
M0540361683
M0540391158
M0540603145
M0540603145
M0540603154
M0540603260
M0540603428
M0540605576
M0540605637
M0540643248
M0540990332
M0540990332
M0541404305
M0542990129
M0544625132
M0590469999
M1147200214
M1147400500

SPIRALWOUNDMETALGASKETSS30478X93.4X
SPIRLWDMETGASKW/OOUTRRINGSIZE40
PKGG:IS:4687/1DRYASM:RN:10
PKGG:IS:4687/3LB&GRASHPR:RN:6MM
PKGG:IS:4687/3LB&GRASHPR:RN:12
PKGG:IS:4687/3LB&GRASHPR:RN:12
PKGG:IS:4687/3LB&GRASHPR:RN:13.5
PKGG:IS:4687/3LB&GRASHPR:RN:28MM
PKGG:IS:4687/3LB&GRASHPR:RN:28MM
PKGG:IS:4687/3LB&MIASHPR:RN:6.4
6MMSQGLANDPACKINGSTYLE376
6MMSQGLANDPACKINGSTYLE376
PCKGL:NSIMILAR2300):SQR:18.6X31.2
PCKGL:(SIMILAR2300):SQR:10
PCKGL:(SIMILAR2300):SQR:16
PCKGL:(SIMILAR2300):36X51
PCKGL:(SIMILAR2300):36X55.8
PCKGL:N.,NONGRAPTDCH.1960:SQR:9.5
GRAPHITELUBRICATEDSSWIREREINFORCEDC
GRAPHITELUBRICATEDSSWIREREINFORCEDC
GLANDPKGRINGMAT33X20X7MM
ASB.REINF.WITHINCONEL/SSWIREGLANDPAC
GLANDPKGRINGGRAPH25.4X12.7X5MM
PCK.CLOTH:CPCLADASBESTOSGKTFOROGUN
OTHERLUBRI:SEMISOLID:MOLYKOTEHSC
OTHERLUBRICANTSFORMSPRAYOKS241

NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
KG
CS
8

Qty

Amount
100
100
55
60
200
30
600
150
120
200
200
50
90
100
150
100
200
100
200
120
100
300
400
500
10
10

4,231.83
1,258.94
3,768.92
188.17
5,625.30
1,068.79
13,212.69
506.28
355.08
708.79
1,012.55
313.65
555.18
1,350.07
19,454.74
1,056.66
3,375.18
1,563.35
5,737.81
4,431.39
506.28
1,012.55
1,350.07
1,147.50
43,693.12
2,550.00

Ramagundam
M1149200885
M1149200885
M1149200885
M1149200885
M2730250029
M2801990039
M2801990039
M2801990039
M4725010003
M4725010003
M4725070007
M4725070007
M4725070089
M4725070195
M4725070308
M4725330188
M4725330507
M4725340137
M4725340199
M4725340205
M4725350078
M4725350081
M4725420025
M4725430026
M4725430081
M4725430106
M4725430106
M5101126060
M5105020014

HSDVehicle
HSDVehicle
HSDVehicle
HSDVehicle
MARKEENCLOTHWIDTH90CM3640GMS/SQ.MTR
WHITECOTTONYARNWASTE(TEASED)
WHITECOTTONYARNWASTE(TEASED)
WHITECOTTONYARNWASTE(TEASED)
DISCFORDRUMSAFTYV/V1740OF500MW
DISCFORDRUMSAFTYV/V1740OF500MW
CSEALRNGFORERVISOLGV/VBHEL
CSEALRNGFORERVISOLGV/VBHEL
SEATBUSHGGKTFORERV1538VX
PILOTV/VDISCFORRHOUTLT6ERV
DISCFORMAINVALVEOFERV1538VX10W
GASKETSETSH.ATP.CONTV/V.SNO2815854
GLANDPKGFORU7SHSCVSD4043
GASKETSETRH.ATPCONTV/VSNO.2815939
COUPGFORRHCVSBOMO5SMA3H0120
GLNDPKGFORU7RHSPRAYCVSD4952
GLANDPKGSETFOR40%SB.CONTV/V.
GLANDPKGFORSB.CONTV/V.S.NO.2817468
gasketsetofSHAtepblkV/VS.NO2815836
GASKETSETRHATTEPBLKV/VSNO2815820
GLNDPKGFORRHSBVSD4548
VALVETRIMFORRHBRANCHBLCKV/V
VALVETRIMFORRHBRANCHBLCKV/V
PRESSURESEALGASKETFORCRHNRV
STEM&DISCASSEMBLY25NB,F22,2500CL

L
L
L
L
M
KG
KG
KG
NO
NO
NO
NO
NO
NO
NO
SET
NO
SET
NO
NO
SET
SET
SET
SET
NO
SET
SET
NO
NO
Total
9

3
10
10
5
10
3
10
5
1
2
1
3
3
1
1
2
2
2
6
2
1
1
1
2
2
1
1
1
1

115.21
401.76
399.67
203.95
0
89.79
299.29
149.65
8,567.39
17,134.78
30,092.01
90,276.04
10,221.83
3,878.80
24,078.00
20,309.87
2,307.50
7,960.19
1,716.00
2,307.50
16,318.39
16,318.40
13,100.21
7,960.19
3,907.00
47,341.75
47,341.75
35,782.50
3,813.33
5,32,427.64

Ramagundam

DuctsOHWorks:

MaterialCode

MaterialDescription

Unit

M0105160128
M0135102525
M0135105029
M1613342370
M1613348527
M1613355439
M1514145821
M1515142560
M1515146429
M1525244012
M1528342960
M1515142870

ANGLEEQIS:2062E250AFE410W75X6MM
PLATEMSIS:2062E250AFE410W5MM
PLATEMSIS:2062E250AFE410W10MM
PMSB2:IS:1239PT1H:80X88.9:4.50
PMSB2:IS:1239PT1H:100X114.3:7.10
PIPEMSBLPII:1239PT1H:125X146:5.40MM
SCREWHEXHT:IS:1364:COARSEMC:24X65MM
8.8HTFTHREADHEXHD.BOLT/NUTM10X100
BOLTH.HD:IS:13648.8:24X100
STUDFERROUSIS1862P.C.8.8M16X100
STUDFERROUSTHREDED:IS:1862H.T12X80
BLTHEXHT:IS:1364:MC:12X60MM

MT
MT
MT
M
M
M
NO
NO
NO
NO
NO
NO
Total

Qty

Amount
2.93
8.02
2.3
61.45
330.22
99.2
200
200
100
300
300
1,500

1,06,062.10
3,30,244.59
95,883.32
21,836.26
1,94,225.50
64,080.22
9,180.00
2,142.00
6,517.80
6,089.40
2,417.40
13,045.38
8,51,723.97

ReplacementofNMEJ
MaterialCode

MaterialDescription

Unit

M4748130032
M4748130023

NONMETLCEXPNJNTFABCKEB2005IN
NONMETLCEXPNJNTFABCKEB2005IN

M
M
Total

10

Qty

Amount
35
35

2,41,073.12
4,39,954.04
6,81,027.16

Ramagundam

Insulation&Refractory:
MaterialCode

MaterialDescription

Unit

M0362454501
M0440310509

SLABBONM:IS:8183:BULK150:50MM
REF/INSUCAST:MONOLFIR:Al2O3&Fe2O3

M2
MT
Total

Qty

Amount
1,334.17
2

2,04,313.92
28,469.92
2,32,783.84

HangersReplacementinCRHLine:
MaterialCode

MaterialDescription

Unit

M4715016014

H&SITEM:HANGERASSY.

NO
Total

11

Qty

Amount
8

16,52,000.00
16,52,000.00

Ramagundam

UNIT 7 OVERHAUL 2010 EXPENDITURE:

Sl.
No.

WorkDescription

P.O.No.

Agency

Works

Material

Total

3475070.50

1584064.43

5059134.93

2455525.43

1145109.89

3600635.32

227022.26
148844.34

0.00
0.00

227022.26
148844.34

HP tube replacement Pass1 &

Burner repair

HP tube replacement Pass2

3
4

Tube thickness survey

HP Jet cleaning

M/s Brothers Engg & Erectors

Ltd.
4000039090 M/s Sans Inpection
4000039076 M/s Nutech Jetting

Erection of quick erect scaffolding

4000044132 M/s Prabhat Engineering Works

663815.20

0.00

663815.20

Pressure setting of safety valves

4000038103 M/s Nicco Engineering Services

61768.00

0.00

61768.00

7
8

4000041949 M/s Hydraulic Valves

4000042283 M/s ABC Engineering Works

204619.45
1046693.21

532427.64
232783.84

737047.09
1279477.05

4000030401 M/s Noorie Engineering Works

967622.38

851723.97

1819346.35

10
11

Servicing of HP valves
Refractory & Insulation works
Maint. Of LRSBs, Burners & Misc.
works
Ex BHEL Services
Repl. Of Hangers in unit 7

241936.43
385608.80

0.00
1652000.00

241936.43
2037608.80

12

Repl of NMEJ in Unit7

4000039630 M/s ABC Supevisory Services

4000047790 M/s Noorie Engineering Works
M/s KE Burgmann Flexibles
4000050384
India pvt Ltd.

49635.00

681027.16

730662.16

4000048461 M/s Fab Erectors

4000049014

9928161.00

12

6679136.94 16607297.94