COS-ISO-00-OGN/OPS/MECH/031 Rev. No.

: 0 March, 2000

OPERATION GUIDANCE NOTE

CARE AND MAINTENANCE OF TURBINE PLANT FEED SYSTEM

OPERATION SERVICES DIVISION

National Thermal Power Corporation Ltd

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 OF TURBINE PLANT FEED SYSTEM

Approved for Implementation by .. Director ( peration! Date: .. "n#$irie% to : &ead of 'orp. peration (ervice%

CARE AND MAINTENANCE OF TURBINE PLANT FEED SYSTEM

INDE'
S No Content! 1.0 &.0 3.0 INTRODUCTION SUPERSEDED DOCUMENTS RECORDS OF FEED SYSTEM STATUS *.) b+ective *.2 Information Re#$ired ENGINEERING ASPECTS OF PLANT OPERATION ,.) b+ective% ,.2 -he Infl$ence of peratin. 'ondition on 'omponent /ife ,.* "%%ential 0rotection for ther 0lant 1rom 1a$lt% ri.inatin. in the 1eed (y%tem ,., Re#$ired Monitorin. In%tr$mentation ,.2 Interim Arran.ement% ,.3 peratin. /imit% PLANT MAINTENANCE AND MODIFICATION 2.) b+ective% 2.2 0lanned Maintenance Activitie% 2.* 0reventive Maintenance 2., Modification% LIFE ASSESSMENT 3.) b+ective% 3.2 '$m$lative -$be 1ail$re 3.* 'rac6 7ro8th and -hermal 1ati.$e 3., In%pection 0roced$re% REVIEW Pa"e No ) ) ) ) ) * * , 2 3 3 3 4 4 4 5 5 5 5 5 9 )0 )0

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APPENDI' A. :) :2 :* :, :2 Definition of (tart 'ate.orie% 1ormat of -$rbine 1eed (y%tem (tat$% Record% 1eed (y%tem (tat$% Record perational &i%tory In%pection ; Maintenance R$nnin. Record% )) )2 )* ), )2 )3

Page - 1 COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care 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 e-c#!ding t(e 'ain )!')ing !nit& and t(eir re&)ective drive& .e.g. conden&ate e-traction )!')&+ 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/ ii/ iii/ 0o* )re&&!re.0P/ (eater&+ &!rface t%)e 1eaerator& Hig( )re&&!re.HP/ (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%. O)ti'i&ing o)erating condition& and t(ere"% 'ini'i&ing t(e rate of co')onent deterioration. 1eter'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. En&!ring t(at ro!tine 'aintenance and an% re'edia# action e')#o%ed give t(e greate&t overa## "enefit.

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SUPERSEDED DOCUMENTS

Ni#
3. 3.1 RECORDS OF FEED SYSTEM STATUS Objective (e o"3ective 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 National Thermal Power Corporation Ltd.

Page - 4 COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' &%&te'. 6 data"a&e &(o!#d "e &e#ected fro' t(i& #i&t (aving d!e regard to t(e #eve# of infor'ation avai#a"#e fro' 'an!fact!rer& for eac( individ!a# &%&te'. 3.2.1 O"i(in$) De*i(n Intent i/ ii/ iii/ iv/ v/ Heater t%)e& 1iagra''atic arrange'ent of feed &%&te' 7a#ve &c(ed!#e Genera# arrange'ent& of eac( (eater 1etai# 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 fi-ing& d/ 8ater"o-/divi&ion )#ate e/ 1eaerating (ead/tra%*or, and/or &)ra% no99#e detai#& f/ :#ed &tea' )i)e*or, g/ Conden&ate/feed )i)e*or, (/ 1rainage )i)e*or,.inc#!ding orifice& if fitted/ i/ 1rain& receiver& 3/ Pre&&!re re#ief va#ve ca)acitie& and &etting& ,/ ;!a#it% #i'it& for )i)e*or, "end& O)erating condition& for eac( &tage .inc#!ding ta))ing )oint& and condition& for "#ed &tea'/. Reco''ended rate& of te')erat!re c(ange acro&& (eav% &ection&.

vi/ vii/ 3.2.2

M!'i ic$ti!n t! O"i(in$) De*i(n Inc#!de detai#&+ *it( f!## &!))orting dra*ing&+ of a## 'a3or 'odification& to t(e origina# de&ign e.g. )i)e*or,/va#ve 'odification&+ additiona# va#ve&+ "a&ic de&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/ ii/ iii/ iv/ v/ Heater &(e##&/t!"e)#ate&/(eader& !"e& Conden&ate / feed )i)e*or, :#ed &tea' )i)e*or, 7a#ve& National Thermal Power Corporation Ltd.

Page - 3 COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' S)ecific attention to "e dra*n to a## va#ve& in ca&t iron. S!))ort detai#& on a## 'a3or )i)e*or,. 1etai#& of ,no*n defect& acce)ted on co''i&&ioning. 3.2.+ O,e"$ti!n$) -i*t!". i/ ii/ iii/ iv/ v/ vi/ 3.2./ 1ate of in&ta##ation of origina# &%&te'. 1ate of in&ta##ation of e-i&ting &%&te' *(ere it differ& fro' t(e a"ove. O)erating (o!r& of #a&t in&)ection. N!'"er& of (ot+ *ar' and co#d !nit &tart& at #a&t in&)ection+ *it( "e&t 3!dge'ent of feed train &tart&+ a& defined in 6))endi- 6. %)ica# 'a-i'!' 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&. 6 "rief &!''ar% of )ro"#e' area& and fai#!re& e-)erienced to date.

In*,ecti!n $n' M$inten$nce i/ ii/ 1ate& of )a&t in&)ection&. S!''ar% of finding& in eac( ca&e inc#!ding : a/ Co')onent/area in&)ected "/ Met(od of in&)ection c/ Re&!#t& d/ 6ction ta,en Co')onent& re)#aced *it( date 1ate of ne-t )#anned in&)ection C!rrent e&ti'ate of re'nant #ife Percentage ova#it% of )i)e*or, "end& 1ate 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/ 1etai#& of an% "efore-and-after )erfor'ance 'onitoring 1ate of ne-t )#anned c#eaning o)eration $or &!rface-t%)e (eater& on#% : - 1ate of t!"e fai#!re& )#!& #ocation inc#!ding (eig(t a"ove/fro' t!"e)#ate face if 'ea&!red. - 1etai#& of t!"e )#!gged )#!& 'et(od !&ed - <)dated diagra' of )#!gging &it!ation

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EN0INEERIN0 ASPECTS OF PLANT OPERATION Objective* o define t(e in&tr!'entation re2!ired : National Thermal Power Corporation Ltd.

Page - = COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' i/ ii/ o )rovide o)erating #i'it& t(at *i## 'ini'i&e co')onent deterioration+ and o )rovide e&&entia# )rotection for ot(er area& of )#ant fro' fa!#t condition& ari&ing in t(e feed &%&te'.

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T1e in )&ence ! !,e"$tin( c!n'iti!n* !n c!#,!nent )i e 6& a co')#e-+ integrated &%&te'+ t(e feed &%&te' co')onent& can "e &!"3ected to t*o di&tinct t%)e& of #ife-#i'iting 'ec(ani&'&. (e&e can "e c#a&&ed a&: i/ ii/ 1irect 'ec(ani&'&+ i.e. t(o&e ca!&ed direct#% on a co')onent "% offde&ign e-c!r&ion& o!t *it( t(e feed &%&te'. Indirect or ,noc,-on 'ec(ani&'& *(ere a co')onent i& &!"3ect to deterioration 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"ect2Actin( Mec1$ni*#* (e 'a3or direct-acting 'ec(ani&' affecting feed (eater #ife i& t(er'a# fatig!e. (e rate of c(ange of &!rface te')erat!re on t(e (eav% &ection&+ )artic!#ar#% of HP &!rface-t%)e (eater& can give ri&e to e-ce&&ive te')erat!re gradient& acro&& t(e &ection. (i& co!)#ed *it( &tre&& concentrating feat!re& &!c( a& &'a## radia# c!rve& or coar&e 'ac(ining 'ar,& can #ead to (ig( &train+ #o* c%c#e fatig!e crac,ing. In e-tre'e ca&e&+ ra)id (eating or coo#ing tran&ient&+ co!)#ed *it( e-i&ting crac,& or defect&+ can #ead to fa&t "ritt#e fract!re. +.2.2 In'i"ect Mec1$ni*#* So'e e-a')#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## 3oint& vii/ $ai#!re of *ater"o- divi&ion.)artition/ )#ate integrit%/&ea#ing National Thermal Power Corporation Ltd.

Page - 5 COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' $o!#ing on eit(er &!rface *i## red!ce t(e (eat tran&fer coefficient .H C/ 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 fi-ed "aff#e )#ate& or+ in e-tre'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 concerned and 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(eating or 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&ate dro)#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 e-ce&&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 'a3or *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!&. $ai#!re of t(e integrit% of t(e *ater"o- divi&ion )#ate .)artition )#ate/+ or it& &ea#+ #ead& to invo#!ntar% "%)a&&ing of t(e t!"e ne&t and con&e2!ent #o&& of feed o!t#et te')erat!re. +.3 E**enti$) P"!tecti!n !" Ot1e" P)$nt "!# F$&)t* O"i(in$tin( in t1e 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"ine .eit(er a 'ain t!r"ine or a :oi#er $eed P!') !r"ine .:$P /. National Thermal Power Corporation Ltd.

Page - A COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' (e &it!ation can ari&e fro' eit(er a "#oc,ed (eater drain& &%&te' or a '!#ti)#e t!"e fai#!re in a &!rface t%)e (eater. (e ingre&& of *ater into t!r"ine and t(e on-#oad te&ting re2!ire'ent& detai#ed t(erein+ )artic!#ar#% *it( regard to t(e d!)#icate f#oat &*itc(e&+ &(o!#d "e rigid#% ad(ered to+ for t(e on-#oad te&ting of "#ed &tea' non-ret!rn va#ve&. +.+ Re%&i"e' M!nit!"in( In*t"&#ent$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/ $eed *ater f#o* .)er train if avai#a"#e ot(er*i&e tota# feed f#o*/ iv/ :#ed &tea' te')erat!re at (eater in#et v/ Heater &(e## )re&&!re vi/ 1rain& o!t#et te')erat!re 6## t(e a"ove &(o!#d "e avai#a"#e to t(e o)erator and recorded "% t(e Station on a 'ont(#% "a&i& for f!t!re ana#%&i&/a!dit )!r)o&e&. In addition+ t(e conden&ate #eve# in a## (eater& &(o!#d "e c#ear#% indicated #oca# to t(e (eater and+ de&ira"#%+ at t(e o)erator?& contro# de&,. +./ Inte"i# A""$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/ ii/ iii/ iv/ v/ vi/ $eed *ater in#et te')erat!re $eed *ater o!t#et te')erat!re $eed *ater f#o* :#ed &tea' te')erat!re Heater &(e## )re&&!re 1rain& o!t#et te')erat!re

+.3 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&.

National Thermal Power Corporation Ltd.

Page - B COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' O)erating in&tr!ction& &(o!#d "e dra*n !) for eac( &tation+ "a&ed on data on (eater 'eta# te')erat!re& ver&!& feed in#et te')erat!re&+ gat(ered fro' t(e in&tr!'entation. (e o)erating in&tr!ction& &(o!#d "e defined in ter'& of #engt( of )receding &%&te' o!tage and avai#a"#e feed *ater in#et te')erat!re. (e rate of a))#ication of "#ed &tea' *i## "e dictated "% t(e ca)acit% of t(e drain& contro# &%&te' to 'aintain contro# of (eater #eve#& *it(in t(e nor'a# o)erating range. /. /.1 PLANT MAINTENANCE AND MODIFICATION Objective* o identif% t(e content and ti'ing of )#anned 'aintenance+ to o!t#ine a )roced!re for for'!#ating c#eaning/in&)ecting/re)air/ref!r"i&('ent &c(e'e&@ to identif% t(e con&ideration& regarding t(e introd!ction of 'odification&. /.2 P)$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/ ii/ iii/ Integrit% of feed in#et+ o!t#et and "%)a&& i&o#ating va#ve&. (e condition of )i)e*or,+ and ade2!ate &!))ort &%&te'&. N1 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& ad3acent to "ranc( )i)e&+ acce&& door rece&&+ *ater"o- to )i)e *e#d&+ e-terna# 3!nction of *ater"o- and "ranc( )i)e& and t!"e)#ate #iga'ent& and t!"e )#ate. !"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 N1 in&)ection i& re2!ired. 6n% )artic!#ar e'erging )attern of t!"e fai#!re&+ t(e degree and rate of t!"e fai#!re 'a% indicate t(e need for t!"e-*a## t(inning &!rve% !&ing a))ro)riate tec(ni2!e.

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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 National Thermal Power Corporation Ltd.

Page - C COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' re&!#t& of t(e&e in&)ection& &(o!#d "e recorded in t(e feed &%&te' &tat!& record& .6))endi--:1 to :5/. /.3 P"eventive M$inten$nce 8(ere a )artic!#ar area of a ne&t (a& "een identified a& "eing )rone to on-#oad t!"e fai#!re+ a t!"e*a## t(inning in&)ection &(o!#d "e carried o!t on t(i& and ot(er &i'i#ar (eater&. 1e)ending on t(e rate of t!"e fai#!re& and on t(e origina# t!"e *a## t(ic,ne&&+ a #eve# >a##o*a"#e *ear? *i## "e e&ta"#i&(ed+ *it( a## t!"e& detected *it( greater *ear "eing &acrificia##% )#!gged. /.+ M!'i ic$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 e-i&ting t!"e)#ate / (eader to t(e origina# ne&t de&ign. ii/ Re-t!"e of t(e e-i&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 / (eader integrit% "eing e&ta"#i&(ed "% co')re(en&ive N1 . iii/ Re-t!"e of a ne* t!"e)#ate / (eader "!t !&ing t(e e-i&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 e-i&ting )i)e*or, and &!))orting &tee#*or, and fo!ndation &tr!ct!re&. 3. 3.1 LIFE ASSESSMENT Objective* o define a 'et(odo#og% for deter'ining t(e degree of co')onent degradation and identif% t(e action re2!ired to a&&!re contin!ed &afe+ efficient o)eration to a )redicta"#e #i'iting #ife. 3.2 C&#&)$tive T&be F$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 3!&tification for )#ant re)#ace'ent in t(i& ca&e *i## "e 'ade on econo'ic gro!nd&.

National Thermal Power Corporation Ltd.

Page - D COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' 6n a&&e&&'ent &(o!#d "e 'ade+ for eac( &tage of feed (eating+ of a dat!' #eve# of )ercentage &!rface #o&& a"ove *(ic( a )#ant re)#ace'ent &c(e'e 'ig(t "eco'e via"#e. (i& a&&e&&'ent &(o!#d a#&o ta,e into acco!nt "ot( c!rrent and )redicted rate& of t!"e fai#!re&+ and )ro"a"#e #ead-ti'e re2!ired to o"tain re)#ace'ent )#ant. (e re&!#t& of t(i& a&&e&&'ent for eac( (eater &(o!#d "e entered in t(e feed &%&te' &tat!& record&. Once an% (eater (a& reac(ed it& dat!' #eve#+ a &)ecific a&&e&&'ent of t(e financia# ca&e for it& re)#ace'ent &(o!#d "e carried o!t. S(o!#d t(i& ca&e fai# to 'eet c!rrent criteria+ t(e e-erci&e &(o!#d "e re)eated at #ea&t ann!a##%+ !nti# &!c( ti'e a& a ca&e can "e 'ade. 3.3 C"$c5 0"!6t1 $n' T1e"#$) 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(e crac, 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# N1 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#ar in&)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& not nece&&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!tage in&)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 rein&)ection.

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Page - 10 COS-ISO-00-OGN/OPS/MECH/031 Rev. No.: 0 Care and Maintenance of !r"ine P#ant $eed S%&te' (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#&+ and in(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&. 3.+ 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 N1 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*ing t(i& doc!'ent on a 3 %ear#% "a&i&+ or a& and *(en re2!ired.

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APPENDI:2A

DEFINITION OF START CATE0ORIES (e categorie& defined "e#o*+ re)re&ent "e&t c!rrent )ractice and &(a## "e ado)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 e-ceeding B4 (r&. .'eta# te')erat!re& "e#o* =0E 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 =0E and C0E of t(eir f!## #oad va#!e& in 0 C/. iii/ Hot &tart+ after a &(!tdo*n )eriod of #e&& t(an 10(.'eta# te')erat!re& a"ove C0E 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:2B1

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## e-i&t. (e fo##o*ing for'at i& )re&ented a& an ade2!ate e-a')#e+ for an i'aginar% ca&e *(ere t(e i')ortance of t(e )#ant invo#ved (a& 3!&tified a f!## i')#e'entation of t(i& code of )ractice+ "!t *(ere no 'a3or (a9ard i& recogni&ed and *(ere t(e #ife #i'itation i& a#read% identified *it( ade2!ate engineering and "!dgetar% )rovi&ion in (and. It *i## "e &een t(at t(e &!gge&ted for'at doe& not ca## for a## re#evant doc!'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 e-tre'e *i## "e *(ere a )er'anent di&)en&ation regarding i')#e'entation (a& "een agreed.

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APPENDI:2B2

FEED SYSTEM STATUS RECORD S E6M SO<RCE 0P3 0P4 0P1 HE6 ER 0PH-1 0PH-4 0PH-3 1ESIGN P6R IC<06RS

IP / 0P / CROSS-<N1ER / O :$P / 1/6 O7ER / 6RO<N1 IP1 CRH HP1 M6N<$6C <RER: HE6 ER FPES: 1ES<PERHE6 ERS: 1R6INS COO0ERS: HPH-5 HPH-A HPH-B

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APPENDI: B23

OPERATIONAL -ISTORY i/ ii/ iii/ iv/ <nit& in&)ected and date& O)erating (o!r& at #a&t in&)ection N!'"er of (ot+ *ar' and co#d &tart& to date Ma-i'!' 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&.

PROBLEM AREAS P06N 6## HP (eater& HP (eater drain& PRO:0EM 8ater"o- circ!'ferentia# crac,ing Pi)e ero&ion and fai#!re of NR7

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INSPECTION AND MAINTENANCE

16 E 6N1 <NI INSPEC E1

COMPONEN / 6RE6

$I0E / REPOR NOS. 60 ERN6 I7E SO<RCES

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APPENDI:2B/

RUNNIN0 RECORDS <NI G.. Heater $EE1 IN .OC/ $EE1 O< .OC/ EI N.S E6M IN .OC/ EI N.PRESS. .HSC/ 1R6INS .OC/ SHE00 PRESS<RE .HSC/ HE6 ER $EE1 IN .OC/ $EE1 O< .OC/ EI N.S E6M IN .OC/ EI N.PRESS. .HSC/ SHE00 PRESS<RE :6R .HSC/ 1C1 1C4 1eaerator 0O61 M8 $EE1 $0O8GG..Hg/&

National Thermal Power Corporation Ltd.

1oc!'ent for 1i&tri"!tion to :

CONTROLLED I. Po,e" S! !-o./
1. General Manager 2. General Manager 3. General Manager 4. General Manager 5. General Manager $. General Manager &. General Manager (. General Manager +. General Manager 1.. General Manager 11. General Manager 12. General Manager 13. General Manager 14. General Manager 15. 0ddl. General Manager(23 # 1$. 0ddl. General Manager(23 # 1&. 0ddl. General Manager(23 # 1(. 0ddl. General Manager(23 # 1+. 0ddl. General Manager(23 # 2.. Dy. General Manager(23 # 21. Dy. General Manager(23 # Rihand Vindhyachal Kahalgaon Farakka Dadri ( oal ! Ga"# %nchahar Kor'a Ra)ag*nda) ,adar-*r /alcher Kaniha 0nta /alcher /her)al Kaya)k*la) 1i)hadri 1ingra*li Ka4a" ,05 6 a-ti7e 0*raiya 8hanor Gandhar Farida'ad /anda

UNCONTROLLED II Re0-o. 1 He 2 34 "!e"/

22. 9:ec*ti7e Director (NR#; 0llaha'ad 23. 9:ec*ti7e Director (1R#; <ydera'ad 24. 9:ec*ti7e Director (=R#; M*)'ai 25. 9:ec*ti7e Director (9R#; >atna 2$. 9:ec*ti7e Director (N R#; Ne4 Delhi

III Co"5o" !e He 2 34 "!e"

2&. hair)an ! Managing Director; 1 6>9; Ne4 Delhi 2(. Director (/echnical#; 1 6>9; Ne4 Delhi 2+. Director (6-eration"# ; 1 6>9; Ne4 Delhi
#$.

Director ( o))ercial#; 1 6>9; Ne4 Delhi

31. Director (>ro?ect"# ; 1 6>9; Ne4 Delhi 32. 9:ec*ti7e Director (61#; 96 ; Noida 33. 9:ec*ti7e Director (9ngg.#; 96 ; Noida 34. General Manager (R!D#; Noida 35. oncerned Gro*- <ead" in 6-eration 1er7ice";

IV He 2 o6 O7M
3$. 1ingra*li 4.. Vindhyachal 44. %nchahar 4(. ,05 6 a-ti7e 5$. 1i)hadri 3&. Kor'a 41. Rihand 45. /alcher Kaniha 4+. 0*raiya 5&./anda 3(. Ra)ag*nda) 42. Kahalgaon 4$./alcher /her)al 5.. 0nta 54. Kaya)k*la) 3+. Farakka 43. Dadri( oal# 4&. ,adar-*r 51. Ka4a" 55. Farida'ad

52. 8hanor Gandhar 53. Dadri (Ga"#