Shutdown Observation Report - M/s SRHHL

14 Aug 2021

Mr Karuppaiah (Mechanical) and Mr Dhanaraman (Instrumentation) Visited M/s SRHH, Kurnool, AP. Plant on
dated 11th Aug to 14 Aug 2021 for Shutdown inspection and observations.,

Grid – Air Nozzle Refractory Dismantling and Dents on Tubes

The Secondary air nozzle holes are got enlarging During refractory dismantling by chipping machine it was
and will increase the pressure drop and Fan Loading observed few dents on tubes and its leading to thinning.
and back shifting of material, Need to replace the Before Hydro Test dedicated inspection and rectification to
enlarged hole nozzle. be done.

Ash Fouling and Scaling on Super Heater Tubes The Available coal at Yard is high GCV Coal but the alkali in
It was observed fouling of ash on Super heater Fuel Ash is high (6%) leads to Fouling in Super heater Tubes.
tubes due to presence of high alkalises (Na2O
+ K2O) in ash of last coal consignment. Ash Analysis
 Shutdown Observation Report - M/s SRHHL
Previously (MV EOLUS) used coal is low GCV but
alkali in Fuel Ash is less (1.4%) Preferred to low alkali
fuel 1.5-2%
Cyclone – Refractory
Refractory condition at Cyclone inlet, Target walls
need to repair
Air Ingress Points
All air ingress points and Instrument tapping flanges
to be provided to reduce the Fan Loading
Furnace – Refractory
Refractory condition in Furnace walls found very loose and
during hammer test, Need to repair with dense castable
refractory with high resistance to abrasion and proper
application by Casting/ Ramming. Need to inspect after
scaffolding inside furnace
Second Pass - Refractory
Refractory Falling is noticed on Second pass need to repair (
Under Progress)
Fans – Suction Filter
Suggesting to conduct maintenance of all fan suction filter
to any restrictions and reduce Fan loading
 Shutdown Observation Report - M/s SRHHL

ESP – High Ash Fouling in Collecting Electrode ESP – The Emitting Electrode pins got dislodged and bend
requires cleaning and Rapping inspection and requires
Testing required

High Flue Gas Exit Temperature

1. Under Performance of Sonic Soot blowers, Suggesting for Servicing and Maintenance of all Sonic Soot
blower – Recommended for Partially retractable soot blower at Economiser, instead of Sonic Soot Blower
2. 100% Air cleaning required in between the staggered tubes
3. Increase Soot Blower Frequency during operation

Exhaust Pressure High

1. High Steam flow exhaust during process steam cut off and increased condenser loading is raising the
exhaust pressure high
2. Inspection required in all Vacuum Line like Ducting and LP Heater steam extraction and Flash tank
connection required
3. 1st Ejector and 2nd Ejector (Secondary condenser) is in line during operation will increase the steam
consumption hence suggesting for CD Nozzle inspection and cleaning
4. CW Pump Inspection required for Head and Flow
Boiler Logics
1. Boiler Purge Logics is not available
2. CO Vent Valve in Wind Box for CO Removal during Plant Trip / Black out
3. Boiler Auxiliaries Supervisory parameters for Equipment safety interlocks

Steam Drum
1. Based on Water & Steam Property the Presence of Phosphate is high 19-20ppm, need to control the
excess phosphate to avoid phosphate based corrosion/deposit on Tubes in future
2. Boiler Water PH is also low need to take care
3. Cross check the Boiler Water Phosphate by using Titration Method
 Shutdown Observation Report - M/s SRHHL

Instrumentation Observations.
Turbine HP valve:
1. Servo actuator required stroke checking and calibration from Woodward controller.
Turbine Vibration Sensors:
1. All sensors and cable healthiness to be checked.
2. Vibration sensor is to be calibrated by GE Bentley Nevada test kit.
3. Spiral hose or conduit piping required for sensor cable lying from local JB.
Turbine Local Panel:
1. Local Panel pressure switches and pressure gauge are to be calibrated.
Turbine Casing:
1. Temperature sensor damaged condition, Required to replace sensor and cable
Turbine control Panel W505:
1. Panel cleaning and cable tightness to be done to avoid any loose contact
2. Vibration Monitor removed condition, Need to fixed and taken in line
Turbine Trip SOV:
1. Coil and solenoid valve healthiness to be checked
2. ESV feedback limit switch healthiness to be checked
DCS UPS and Battery:
1. UPS and battery healthiness to be checked
DCS system:
1. Limited I/O available in DCS ,required to upgrade the system to connect more input and outputs
Boiler Drum area:
1. Drum floor transmitters impulse line found rusted condition, required to replace/modify impulse line.
2. Drum Hydra steps all sensors and cable found loose, healthiness to be checked.
Super heater steam header:
1. Thermocouple and cable healthiness to be checked
2. Approach required for thermocouple inspection during plant running
Transmitters and gauges:
1. All transmitters and gauges are to be calibrated.
2. All area Transmitters signal cables are not properly laid.
3. Transmitters required for canopy or cover by polythene sheet to avoid water ingress
Boiler Area:
1. All Thermocouples healthiness are to be checked.
2. Thermocouple found top cover open condition, Need to be covered properly to avoid waterl enter
inside
Control Valves:
1. All control valves required servicing and calibration
ID,PA and SA Fan dampers:
1. Power Cylinders are to be checked and serviced
Boiler O2 Analyzer:
1. O2 Analyzer healthiness to be checked and calibrated