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O & M CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER

This presentation discusses the challenges faced in renovating the wagon tippler at BPSCL, strategies adopted, pre-shutdown activities, job sequence, shutdown scenario, and conclusion of the successful renovation project in 15 days.

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O & M CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER

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  1. O & M CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER Presented by: P. K. Samantaray, Sr. Manager & M. Prasad, Manager Under the Guidance of: Sri R. Kumar, CEO Sri A. K. Singh, GM (Maintenance)

  2. BPSCL – An Overview • Bokaro Power Supply Company (P) Ltd. is a Joint Venture Company of SAIL and DVC, each have 50% equity holding. • Objective of BPSCL is to supply process steam to Bokaro Steel Plant (SAIL) at 100 ata, 39 ata and 8-12 ata: 500-550 Tph and Power as per Annual target. • BPSCL also supplies Sodium Cationated water: 300 Tph • BPSCL has an aggregate installed capacity to generate 338 MW of Power and 2180 TPH of steam. • Manpower strength in BPSCL is 247 (Executive-173, Non-Executive-74) as on 01.07.2019

  3. CAPACITY - Boiler

  4. CAPACITY

  5. Challenges in the O&M of BPSCL • Profound dependence of TPP boilers on BF & CO gases from BSL/SAIL. • Incomplete Combustion due to inconsistent and inadequate supply of BF & CO gases. • Utilization of Fly ash. • The poor health of only Wagon Tippler. • Obsolete technology of TPP Boilers.

  6. Requirement of the Job • Sever cracks were developed at various civil structures. • Frequency of breakdowns increased significantly affecting the avg. detention time. • Capital repair of the wagon tippler was long time due. • Aging of the tippler structures. • Risk of total collapse of tippler requiring very high restoration time.

  7. Details of Wagon Tippler

  8. CHALLENGES IN RENOVATION JOB OF WAGON TIPPLER • Complete dependence of BSL for Power & process steam requirement • Threat of drawing power by BSL from DVC exceeding the contract demand of 220 MVA. • Coal unloading through manual means was not adequate to cater daily coal feeding requirement (5000 MT approx.). • No prior experience/ expertise was available with BPSCL in such renovation job.

  9. Strategies Adopted for Renovation • Identification and completion of all pre-shutdown jobs. • To make all necessary contracts/work orders in place. • Identification and arrangements of all required spares. • To plan round the clock working during shutdown period and maximizing the manpower engagement. • To build healthy coal stock level

  10. PRE-SHUTDOWN ACTIVITIES • Planning of various jobs. • Execution of jobs before the actual shut-down. • Activities were mainly in-house fabrication jobs. • Dismantling of some of the supplied spares for easy handling during erection. • Pre-alignment and assembly of some of the spare parts to save time during erection work. • Transfer of required co-ordinates of wagon tippler. • Resource and material mobilization at site.

  11. JOB SEQUENCE • Duration: From 22/05/2018 to 05/06/2018 (15 days). • Dismantling of complete wagon tippler. • Removal of worn-out foundation frames by breaking RCC foundations. • Erection & alignment of base/foundation frames by level re-transfer followed by casting of base frame by CED. • Erection of rotor (Inhaul side) followed by 1st bottom frame. • Erection & alignment of middle rotor with 1strotor along with erection of pipe frames. • Erection & alignment of 2ndbottom frame followed by last rotor (outhaul side) along with erection of balance pipe frames. • Erection and alignment of gearbox foundation frame followed by casting of the foundation by CED • Erection of both cradle assemblies after welding of bottom frames with rotors. • Erection of both tippler platforms followed by fixing of stay pipes and arms. • Erection of top beams and complete welding of different associated structures. • Removal of all locking structures, fixing and welding of checkered plate and complete welding, painting followed by trial run of the tippler.

  12. Gantt Chart

  13. SCENARIO during Shutdown • Schedule of shutdown planned for 28 days • Coal stock as on 22.05.2018 i.e. at start of the shutdown: 68,201 MT • Coal stock as on 05.06.2018 i.e. at end of the shutdown: 34,313 MT • Number of wagons unloaded manually during shutdown period: 461 wagons • Average generation level during shutdown period: Steam: 1152 TPH (Min. – 1099 TPH, Max.– 1231 TPH) Power: 139.7 MW (Min.– 127 MW, Max. – 159.64 MW)

  14. CONCLUSION • With better co-ordination among all involved agencies, whole pre and post shutdown activities were completed safely in 15 days. • Use of high early strength and self-compacting concrete mortar cum chemicals helped in reducing the overall job time. • Total cost involved: Rs. 34,39,429/- * Mechanical jobs: Rs. 17,83,550/- (excluding cost of spares) * For civil jobs: Rs. 16,55,879/- (including cost of materials) Demurrage charges incurred: Rs. 11,83,350/-

  15. Thank You

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